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FIELD OF THE INVENTION
[0001] The field of this invention relates to suspending one tubular in another, especially hanging liners which are to be cemented.
BACKGROUND OF THE INVENTION
[0002] In completing wellbores, frequently a liner is inserted into casing and suspended from the casing by a liner hanger. Various designs of liner hangers are known and generally involve a gripping mechanism, such as slips, and a sealing mechanism, such as a packer which can be of a variety of designs. The objective is to suspend the liner during a cementing procedure and set the packer for sealing between the liner and the casing. Liner hanger assemblies are expensive and provide some uncertainty as to their operation downhole.
[0003] Some of the objects of the present invention are to accomplish the functions of the known liner hangers by alternative means, thus eliminating the traditionally known liner hanger altogether while accomplishing its functional purposes at the same time in a single trip into the well. Another objective of the present invention is to provide alternate techniques which can be used to suspend one tubular in another while facilitating a cementing operation and still providing a technique for sealing the tubulars together. Various fishing tools are known which can be used to support a liner being inserted into a larger tubular. One such device is made by Baker Oil Tools and known as a “Tri-State Type B Casing and Tubing Spear,” Product No. 126-09. In addition to known spears which can support a tubing string for lowering into a wellbore, techniques have been developed for expansion of tubulars downhole. Some of the techniques known in the prior art for expansion of tubulars downhole are illustrated in U.S. Pat. Nos. 4,976,322; 5,083,608; 5,119,661; 5,348,095; 5,366,012; and 5,667,011.
SUMMARY OF THE INVENTION
[0004] A method for securing and sealing one tubular to another downhole facilitates cementing prior to sealing and allows for suspension of one tubular in the other by virtue of pipe expansion techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIGS. 1 - 4 are a sectional elevation, showing a first embodiment of the method to suspend, cement and seal one tubular to another downhole, using pipe expansion techniques.
[0006] FIGS. 5 - 11 a are another embodiment creating longitudinal passages for passage of the cementing material prior to sealing the tubulars together.
[0007] FIGS. 12 - 15 illustrate yet another embodiment incorporating a sliding sleeve valve for facilitating the cementing step.
[0008] FIGS. 16 - 19 illustrate the use of a grapple technique to suspend the tubular inside a bigger tubular, leaving spaces between the grappling members for passage of cement prior to sealing between the tubulars.
[0009] FIGS. 20 - 26 illustrate an alternative embodiment involving a sequential flaring of the inner tubular from the bottom up.
[0010] FIGS. 28 - 30 illustrate an alternative embodiment involving fabrication of the tubular to be inserted to its finished dimension, followed by collapsing it for insertion followed by sequential expansion of it for completion of the operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] Referring to FIG. 1, a tubular 10 is supported in casing 12 , using known techniques such as a spear made by Baker Oil Tools, as previously described. That spear or other gripping device is attached to a running string 14 . Also located on the running string 14 above the spear is a hydraulic or other type of stroking mechanism which will allow relative movement of a swage assembly 16 which moves in tandem with a portion of the running string 14 when the piston/cylinder combination (not shown) is actuated, bringing the swage 16 down toward the upper end 18 of the tubular 10 . As shown in FIG. 1 during run-in, the tubular 10 easily fits through the casing 12 . The tubular 10 also comprises one or more openings 20 to allow the cement to pass through, as will be explained below. Comparing FIG. 2 to FIG. 1, the tubular 10 has been expanded radially at its upper end 18 so that a segment 22 is in contact with the casing 12 . Segment 22 does not include the openings 20 ; thus, an annular space 24 exists around the outside of the tubular 10 and inside of the casing 12 . While in the position shown in FIG. 2, cementing can occur. This procedure involves pumping cement through the tubular 10 down to its lower end where it can come up and around into the annulus 24 through the openings 20 so that the exterior of the tubular 10 can be fully surrounded with cement up to and including a portion of the casing 12 . Before the cement sets, the piston/cylinder mechanism (not shown) is further actuated so that the swage assembly 16 moves further downwardly, as shown in FIG. 3. Segment 22 has now grown in FIG. 3 so that it encompasses the openings 20 . In essence, segment 22 which is now against the casing 12 also includes the openings 20 , thereby sealing them off. The seal can be accomplished by the mere physical expansion of segment 22 against the casing 12 . Alteratively, a ring seal 26 can be placed below the openings 20 so as to seal the cemented annulus 24 away from the openings 20 . Optionally, the ring seal 26 can be a rounded ring that circumscribes each of the openings 20 . Additionally, a secondary ring seal similar to 26 can be placed around the segment 22 above the openings 20 . As shown in FIG. 3, the assembly is now fully set against the casing 12 . The openings 20 are sealed and the tubular 10 is fully supported in the casing 12 by the extended segment 22 . Referring to FIG. 4, the swage assembly 16 , as well as the piston/cylinder assembly (not shown) and the spear which was used to support the tubular 10 , are removed with the running string 14 so that what remains is the tubular 10 fully cemented and supported in the casing 12 . The entire operation has been accomplished in a single trip. Further completion operations in the wellbore are now possible. Currently, this embodiment is preferred.
[0012] FIGS. 5 - 12 illustrate an alternative embodiment. Here again, the tubular 28 is supported in a like manner as shown in FIGS. 1 - 4 , except that the swage assembly 30 has a different configuration. The swage assembly 30 has a lower end 32 which is best seen in cross-section in FIG. 8. Lower end 32 has a square or rectangular shape which, when forced against the tubular 28 , leaves certain passages 34 between itself and the casing 36 . Now referring to FIG. 7, it can be seen that when the lower end 32 is brought inside the upper end 38 of the tubular 28 , the passages 34 allow communication to annulus 40 so that cementing can take place with the pumped cement going back up the annulus 40 through the passages 34 . Referring to FIG. 8, it can be seen that the tubular 28 has four locations 42 which are in contact with the casing 36 . This longitudinal surface location in contact with the casing 36 provides full support for the tubular 28 during the cementing step. Thus, while the locations 42 press against the inside wall of the casing 36 to support the tubular 28 , the cementing procedure can be undertaken in a known manner. At the conclusion of the cementing operation, an upper end 44 of the swage assembly 30 is brought down into the upper end 38 of the tubular 28 . The profile of the upper end 44 is seen in FIG. 10. It has four locations 46 which protrude outwardly. Each of the locations 46 encounters a mid-point 48 (see FIG. 8) of the upper end 38 of the tubular 28 . Thus, when the upper end 44 of the swage assembly 30 is brought down into the tubular 28 , it reconfigures the shape of the upper end 38 of the tubular 28 from the square pattern shown in FIG. 8 to the round pattern shown in FIG. 12. FIG. 11 shows the running assembly and the swage assembly 30 removed, and the well now ready for the balance of the completion operations. The operation has been accomplished in a single trip into the wellbore.
[0013] Accordingly, the principal difference in the embodiment shown in FIGS. 1 - 4 and that shown in FIGS. 5 - 12 is that the first embodiment employed holes or openings to facilitate the flow of cement, while the second embodiment provides passages for the cement with a two-step expansion of the upper end 38 of the tubular 28 . The first step creates the passages 34 using the lower end 32 of the swage assembly 30 . It also secures the tubular 28 to the casing 36 at locations 42 . After cementing, the upper end 44 of the swage assembly 30 basically finishes the expansion of the upper end 38 of the tubular 28 into a round shape shown in FIG. 12. At that point, the tubular 28 is fully supported in the casing 36 . Seals, as previously described, can optionally be placed between the tubular 28 and the casing 36 without departing from the spirit of the invention.
[0014] Another embodiment is illustrated in FIGS. 12 - 15 . This embodiment has similarities to the embodiment shown in FIGS. 1 - 4 . One difference is that there is now a sliding sleeve valve 48 which is shown in the open position exposing openings 50 . As shown in FIG. 12, a swage assembly 52 fully expands the upper end 54 of the tubular 56 against the casing 58 , just short of openings 50 . This is seen in FIG. 13. At this point, the tubular 56 is fully supported in the casing 58 . Since the openings 50 are exposed with the sliding sleeve valve 48 , cementing can now take place. At the conclusion of the cementing step, the sliding sleeve valve 48 is actuated in a known manner to close it off, as shown in FIG. 14. Optionally, seals can be used between tubular 56 and casing 58 . The running assembly, including the swage assembly 52 , is then removed from the tubular 56 and the casing 58 , as shown in FIG. 15. Again, the procedure is accomplished in a single trip. Completion operations can now continue in the wellbore.
[0015] FIGS. 16 - 19 illustrate another technique. The initial support of the tubular 60 to the casing 62 is accomplished by forcing a grapple member 64 down into an annular space 66 such that its teeth 68 ratchet down over teeth 70 , thus forcing teeth 72 , which are on the opposite side of the grappling member 64 from teeth 68 , to fully engage the inner wall 74 of the casing 62 . This position is shown in FIG. 17, where the teeth 68 and 70 have engaged, thus supporting the tubular 60 in the casing 62 by forcing the teeth 72 to dig into the inner wall 74 of the casing 62 . The grapple members 64 are elongated structures that are placed in a spaced relationship as shown in FIG. 17A. The spaces 76 are shown between the grapple members 64 . Thus, passages 76 provide the avenue for cement to come up around annulus 78 toward the upper end 80 of the tubular 60 . At the conclusion of the cementing, the swage assembly 82 is brought down into the upper end 80 of the tubular 60 to flare it outwardly into sealing contact with the inside wall 74 of the casing 62 , as shown in FIG. 18. Again, a seal can be used optionally between the upper end 80 and the casing 62 to seal in addition to the forcing of the upper end 80 against the inner wall 74 , shown in FIG. 18. The running assembly as well as the swage assembly 82 is shown fully removed in FIG. 19 and further downhole completion operations can be concluded. All the steps are accomplished in a single trip.
[0016] FIGS. 20 - 25 illustrate yet another alternative of the present invention.
[0017] In this situation, the swage assembly 84 has an upper end 86 and a lower end 88 . In the run-in position shown in FIG. 20, the upper end 86 is located below a flared out portion 90 of the tubular 92 . Located above the upper end 86 is a sleeve 94 which is preferably made of a softer material than the tubular 92 , such as aluminum, for example. The outside diameter of the flared out segment 90 is still less than the inside diameter 96 of the casing 98 . Ultimately, the flared out portion 90 is to be expanded, as shown in FIG. 21, into contact with the inside wall of the casing 98 . Since that distance representing that expansion cannot physically be accomplished by the upper end 96 because of its placement below the flared out portion 90 , the sleeve 94 is employed to transfer the radially expanding force to make initial contact with the inner wall of casing 98 . The upper end 86 of the swage assembly 84 has the shape shown in FIG. 22 so that several sections 100 of the tubular 92 will be forced against the casing 98 , leaving longitudinal gaps 102 for passage of cement. In the position shown in FIGS. 21 and 22, the passages 102 are in position and the sections 100 which have been forced against the casing 98 fully support the tubular 92 . At the conclusion of the cementing operation, the lower segment 88 comes into contact with sleeve 94 . The shape of lower end 88 is such so as to fully round out the flared out portion 90 by engaging mid-points 104 of the flared out portion 90 (see FIG. 22) such that the passages 102 are eliminated as the sleeve 94 and the flared out portion 90 are in tandem pressed in a manner to fully round them, leaving the flared out portion 90 rigidly against the inside wall of the casing 98 . This is shown in FIG. 23. FIG. 25 illustrates the removal of the swage assembly 84 and the tubular 92 fully engaged and cemented to the casing 98 so that further completion operations can take place. FIGS. 24 and 26 fully illustrate the flared out portion 90 pushed hard against the casing 98 . Again, in this embodiment as in all the others, auxiliary sealing devices can be used between the tubular 92 and the casing 98 and the process is done in a single trip.
[0018] Referring now to FIGS. 27 - 30 , yet another embodiment is illustrated. Again, the similarities in the running in procedure will not be repeated because they are identical to the previously described embodiments. In this situation, the tubular 106 is initially formed with a flared out section 108 . The diameter of the outer surface 110 is initially produced to be the finished diameter desired for support of the tubular 106 in a casing 112 (see FIG. 28) in which it is to be inserted. However, prior to the insertion into the casing 112 and as shown in FIG. 28, the flared out section 108 is corrugated to reduce its outside diameter so that it can run through the inside diameter of the casing 112 . The manner of corrugation or other diameter-reducing technique can be any one of a variety of different ways so long as the overall profile is such that it will pass through the casing 112 . Using a swage assembly of the type previously described, which is in a shape conforming to the corrugations illustrated in FIG. 28 but tapered to a somewhat larger dimension, the shape shown in FIG. 29 is attained. The shape in FIG. 29 is similar to that in FIG. 28 except that the overall dimensions have been increased to the point that there are locations 114 in contact with the casing 112 . These longitudinal contacts in several locations, as shown in FIG. 29, fully support the tubular 106 in the casing 112 and leave passages 116 for the flow of cement. The swage assembly can be akin to that used in FIGS. 5 - 11 in the sense that the corrugated shape now in contact with the casing 112 shown in FIGS. 29 at locations 114 can be made into a round shape at the conclusion of the cementing operation. Thus, a second portion of the swage assembly as previously described is used to contact the flared out portion 108 in the areas where it is still bent, defining passages 116 , to push those radially outwardly until a perfect full 360° contact is achieved between the flared out section 108 and the casing 112 , as shown in FIG. 30. This is all done in a single trip.
[0019] Those skilled in the art can readily appreciate that various embodiments have been disclosed which allow a tubular, such as 10 , to be suspended in a running assembly. The running assembly is of a known design and has the capability not only of supporting the tubular for run-in but also to actuate a swage assembly of the type shown, for example, in FIG. 1 as item 16 . What is common to all these techniques is that the tubular is first made to be supported by the casing due to a physical expansion technique. The cementing takes place next and the cementing passages are then closed off. Since it is important to allow passages for the flow of cement, the apparatus of the present invention, in its various embodiments, provides a technique which allows this to happen with the tubular supported while subsequently closing them off. The technique can work with a swage assembly which is moved downwardly into the top end of the tubular or in another embodiment, such as shown in FIGS. 20 - 26 , the swage assembly is moved upwardly, out of the top end of the tubular. The creation of passages for the cement, such as 34 in FIG. 8, 76 in FIG. 17A, or 102 in FIG. 22, can be accomplished in a variety of ways. The nature of the initial contact used to support the tubular in the casing can vary without departing from the spirit of the invention. Thus, although four locations are illustrated for the initial support contact in FIG. 8, a different number of such locations can be used without departing from the spirit of the invention. Different materials can be used to encase the liner up and into the casing from which it is suspended, including cement, blast furnace slag, or other materials, all without departing from the spirit of the invention. Known techniques are used for operating the sliding sleeve valve shown in FIGS. 12 - 15 , which selectively exposes the openings 50 . Other types of known valve assemblies are also within the spirit of the invention. Despite the variations, the technique winds up being a one-trip operation.
[0020] Those skilled in the art will now appreciate that what has been disclosed is a method which can completely replace known liner hangers and allows for sealing and suspension of tubulars in larger tubulars, with the flexibility of cementing or otherwise encasing the inserted tubular into the larger tubular.
[0021] The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit of the invention. | A method for securing and sealing one tubular to another downhole facilitates cementing prior to sealing and allows for suspension of one tubular in the other by virtue of pipe expansion techniques. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
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THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
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INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC OR AS A TEXT FILE VIA THE OFFICE ELECTRONIC FILING SYSTEM (EFS-WEB)
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STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINT INVENTOR
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BACKGROUND OF THE INVENTION
This invention relates to sensor arrays, and especially to passive optical sensor arrays that are located in environments in which the sensor array is difficult to access. The invention is particularly suitable for undersea seismic sensor arrays, although it will be appreciated that the invention may be employed with sensors of other types. For example, the array may be employed with electric field sensors for determining the presence of oil by changes in the electric field as the conductivity of the rock that contains the oil changes. In other systems, the array could be part of a security warning system that contains a number of hydrophones for detecting unauthorised vessels.
Undersea seismic sensor arrays are widely used in the exploration of and monitoring of oil and gas reservoirs beneath the seabed. In these seismic monitoring techniques, an array of accelerometers and/or hydrophones are deployed as sensor packages on the seabed and are used to detect reflected seismic waves, and the results are analysed to provide information relating to the nature and state of geological structures beneath the seabed.
Typically a large number of sensors, for example 16,000 or more, are arranged along a number of optical cables that are spaced apart from one another to form a two-dimensional array that extends over a large area for example an area of 100 square kilometers or more. In one form of arrangement which may be referred to as a “4C” sensor unit, three seismic vibration sensors are arranged in orthogonal directions together with one hydrophone to form an optical sensing unit (OSU), and a number of optical sensing units are located along an optical line at spaced apart intervals, for example in the range of from 20 to 100 meters. A number of lines, for example 30 although more or fewer may be employed, may extend from a hub located on the seabed in a direction generally parallel to one another and spaced apart from one another, for example by from 100 to 500 meters, to form the array. The hub may be connected by an optical cable to an interrogator located on an exploration or production platform or on a floating production and storage offloading vessel (FPSO) that monitors the sensors by reflectometry or other interferometric means. The optical cable will contain at least one optical fibre for each of the lines that extend from the hub (typically one fibre pair). In operation, the interrogator sends an optical pulse along the cable where it is split at the hub before being sent along the individual lines to the optical sensor units. The vibration sensors may comprise a length of optical fibre that is wound around a flexible former to form a coil, and the optical lines may contain reflectors, for example formed by a mirror that terminates a fibre spliced with the line, preferably upstream and downstream of the sensors. As the external pressure varies, the coil of fibre is compressed or released, thereby changing the length of fibre in the coil. If a signal is sent along the optical fibre, it is partially reflected back along the line at each of the mirrors so that the signal, for example a phase shift in the signal that is dependent on the distance between the reflectors, is affected by any seismic activity. In this way, any mechanical impulse caused by an air gun or other explosion in the vicinity of the array will cause a phase change in signals reflected by the sensors in the array which may be observed by the interrogator.
The signals that are sent along the optical lines will normally be multiplexed in view of the large number of sensor units, usually both time division multiplexed and wavelength division multiplexed.
The interrogator of the system thus typically comprises a transmitter having a number of light sources such as lasers, e.g. 16 , for forming the optical signals, and optical switches, and a receiver for receiving and processing the reflected optical signals. The receiver will need to demultiplex a number of wavelength and time division multiplexed streams arriving from the various optical lines of the sensor array, convert the optical signals to electrical signals, digitise them and transmit them onwards or store them. The interrogator is normally the only part of the system which contains electronics or requires electrical power.
Such sensor arrays may include a large number of optical fibre pairs, for example 100 to 200 pairs or more depending on the size of the array, and even up to 700 fibres in some cases, and these will extend from the hub to the platform or FPSO in the form of a riser cable which extends generally vertically from the seabed, although there may be a significant horizontal component, whereupon the cable will extend to a receiver unit of the interrogator located on the platform or FPSO.
While such systems generally work well in practice, they can have a number of problems. For example, in some forms of design where the sensor array is a long distance from the interrogator this would require a riser cable with 100 to 200 fibre pairs extending in the region of 100 km or more between the interrogator and the array, which can be impractical and extremely costly. In other circumstances the platform or FPSO may employ existing optical cables for receiving data from the array, in which case it may not have sufficient optical fibres in the riser. For example many installations may employ existing optical cables having only six fibres or so. In yet other instances, it can be difficult to direct the fibres in the cable from the riser to the interrogator and, in many circumstances, such a riser cable termination is not possible. For example, in the case of an FPSO, the riser cable may emerge onto a stationary turntable whereas the rest of the interrogator will be located on the vessel which may rotate about the turntable at least to a limited extent due to tides and currents etc. This will often require some means of allowing the optical fibres to rotate about the axis of the riser cable at least to a limited extent, for example a slip ring otherwise called a fibre optic rotary joint, to allow the optical fibres to extend between the riser cable and the interrogator on the FPSO. However, such slip rings typically only accept a few optical fibres and even the largest number of optical fibres that can be accepted by a slip ring ( 31 at this time) is only a fraction of the number of optical fibres in a typical riser cable, so that seven slip rings would be required. Furthermore, the specification of such a slip ring is insufficient for the purpose of a seismic optical fibre array in many cases since the two-way insertion loss may be 9 dB bringing the insertion loss of the array above 60 dB in some cases. In addition, the minimum return loss of the slip ring may be 18 dB, which means that back reflections my be sent to the array degrading its performance, or alternatively isolators would be required in order to prevent such back reflections. Finally, the physical size of the interrogator may be quite large, in the order of two or three cubic meters, and there may not be enough space on the platform or FPSO for the interrogator.
BRIEF SUMMARY OF THE INVENTION
According to one aspect, the present invention provides a sensor arrangement for monitoring a submarine reservoir, which comprises:
a sensor array comprising a plurality of sensor units located or to be located over an area of the seabed in the region of the reservoir to be monitored; and
an interrogator unit for obtaining data on the reservoir from the sensor units, which comprises a transmitter unit for sending optical signals to the sensor array, and a receiver unit for receiving modulated optical signals from the array in response to the transmitted optical signals;
the transmitter unit comprising an optical switch, for example an acousto-optical modulator (AOM) for receiving optical radiation from an optical source and transmitting optical signals generated thereby along an uplink optical fibre, and at least one splitter for splitting the uplink optical fibre into a plurality of optical fibres that extend to the sensors over the area to be monitored; and
the receiver unit comprising an optical-to-electrical converter for converting optical signals from each fibre of the array to electrical signals, a phase demodulator, a multiplexer for multiplexing the electrical signals from the phase demodulator, and a signal processing and recording unit for recording the multiplexed signals.
The interrogator unit may be divided into a concentrator and an interrogator hub, the concentrator including the splitter and the optical-to-electrical converter, phase demodulator and multiplexer of the receiver unit and the interrogator hub including the optical source and optical switch of the transmitter unit, the signal processing and recording unit, such that the optical source, optical switch, signal processing and recording unit can be located on a platform or on shore, and the electrical-to-optical converter, phase demodulator and multiplexer can be located on the seabed.
The interrogator unit may include means for transmitting signals from the or each concentrator to the interrogator hub along a single line or wirelessly.
The sensor arrangement according to the invention has the advantage that, by dividing the receiver, and preferably the transmitter and receiver, into two parts, one underwater (the concentrator) and the other above water (the interrogator hub), and by multiplexing the signals from the sensor array in the underwater part of the receiver, only a small number of optical fibres are needed in the riser extending between the submerged part of the interrogator and the surface part. The particular number of optical fibres in the riser between the submerged and surface part of the interrogator will depend on the particular design of arrangement, but it is possible to employ only a single optical fibre for the uplink (i.e. from the transmitter to the array) and a single further optical fibre in the downlink (unless the signals are transmitted from the concentrator to the interrogator hub wirelessly) so that the riser contains only a single pair of fibres. Other optical fibres may be necessary or desirable depending on the circumstances as explained below.
The optical fibres extending from the interrogator hub to the array are preferably arranged spatially in proximity to the return fibres extending from the array to the interrogator hub, and especially together so that the sensors are connected to the hub by means of optical cables formed from a pair of fibres. In addition, the interrogator unit may have a number of configurations. For example in one design it may have only a single concentrator from which a number of fibres extend to the sensor array, each line of the array being formed from a pair of fibres. In another design, an optical cable formed from a relatively small number of optical fibres may extend from the interrogator hub to a passive hub where it branches into a number of further optical cables, each extending from the passive hub to a concentrator and typically having two fibres (one uplink carrying transmit pulses and one downlink containing digitised sensor data). From each concentrator the fibres extend to the array as described above. Such a design of array will contain more than two optical fibres in the riser cable, for example up to six or eight fibres or even more, but nothing like the number of fibres employed in prior art systems. Other configurations of array are also possible.
In some circumstances other fibres may be present, for example for sending timing signals to synchronise the transmitter and receiver. For example a further optical fibre for synchronisation may be present extending directly from the transmitter in the interrogator hub to the submerged part of the receiver, that is to say, bypassing the sensor array, although such an arrangement is not preferred since it will increase the number of fibres in the riser. Alternatively, timing signals may be sent from a synchronisation unit in the interrogator hub both to the acousto-optical modulator in the transmitter and to the phase demodulator and/or multiplexer of the receiver unit along the uplink or downlink optical fibre extending along the riser cable. In yet another arrangement, timing signals may be sent along an optical fibre extending on the transmitter side of one or more of the sensors in the array to the phase demodulator, for example in proximity to the downlink optical fibres extending from the array. Only a single such optical fibre is required for a complete array. In addition, it is possible for different fibres in the riser to send signals to and from different parts of the array of sensors depending on the layout of the array, but in such cases it is unlikely for more than six to eight optical fibres to be present in the riser.
It is possible for the concentrator(s) of the interrogator to be permanently secured to the seabed, especially if the electronic parts thereof are relatively simple, but the concentrator could be provided in a watertight module that is submersible and which can be raised up to the platform or FPSO for maintenance or repair but which otherwise remains on the seabed. Such a module may be provided with a stowage/deployment arrangement for stowing the riser cable when the module is raised and for deploying the cable when the module is lowered to the seabed.
Where the concentrator requires electrical power to be supplied, this may be supplied via the link to the interrogator hub, through a separate electrical cable from the platform shore or other seabed location, or via a local battery.
Although the interrogator hub and concentrator will often be located close to each (with one on the surface and one underwater) it is possible for the concentrator and the interrogator hub to be separated from one another, even by a large distance for example by up to 100 km or so.
Although the concentrator is normally located underwater, and the interrogator hub on the surface, in certain circumstances both may be located on the surface, for instance when the concentrator is located on a fixed turret and the interrogator hub on the rotating portion of a floating production platform (FPSO). In these cases, the concentrator is usually located at a location where space and power requirements may be limited, and it is desirable to minimise the number of optical fibres in the connection between the concentrator and the interrogator hub.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
One form of arrangement in accordance with the present invention will now be described by way of example with reference to the accompanying drawings in which:
FIG. 1 is a schematic view of a conventional seismic sensor arrangement;
FIG. 2 is a schematic view of one form of sensor array topography according to the invention;
FIG. 3 is a schematic view of another form of sensor array topography according to the invention;
FIG. 4 is a schematic view of an FPSO in which an arrangement according to the invention may be used;
FIG. 5 is a schematic diagram showing the principal parts of the arrangement according to the invention;
FIG. 6 is a schematic view showing part of the arrangement of FIG. 5 which uses a derivative sensor technique (DST); and
FIG. 7 is a schematic view of an arrangement that employs a submersible module.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , there is seen a marine oil platform 7 , supported on legs from the seabed. A seismic sensor array 1 as described in GB 2 449 941 is deployed on the seabed in order to detect changes in the underlying reservoir. The seismic sensor array comprises a plurality of seismic cables 2 each of which may be formed from a number of modules 3 that are joined by joint elements 4 and contain a number of sensor units 5 that are spaced apart along the cables. The connecting seismic cables 2 lead to a passive hub 8 , where all of the seismic cables 2 are joined to form a riser cable that extends from the hub 8 to an operating system 6 on the platform 7 . Signals are generated by a transmitter in the operating system or interrogator 6 and sent to the sensor units 5 , and returns are received from the sensor units 5 at the operating system 6 , where the signal returns are analysed in order to determine the nature of the structures beneath the seabed. As indicated above, this form of array has the disadvantage that the riser cable will need to employ a large number of optical fibres, for example from 50 to 200 fibres or more.
As shown in FIG. 2 , one form of sensor array similar to that shown in FIG. 1 is shown in which a riser cable 10 comprising just a pair of optical fibres extends from an interrogator hub 11 that is located on the platform and includes a transmitter unit and receiver unit. The cable extends to a concentrator 12 located on the seabed in the region of the platform where the optical fibres in the cable are split to form a number of separate seismic cables 14 corresponding to the cables 2 of FIG. 1 which extend from the concentrator over the region of interest. In addition, a slip ring 15 may be located at the interrogator hub in order to accommodate relative rotational movement between the riser cable and the interrogator hub.
An alternative topography for the sensor is shown in FIG. 3 in which a riser cable 10 comprising in this case six optical fibres extends from the interrogator hub 11 to a passive hub 16 where the optical fibres are divided into three separate optical cables 17 , each having a pair of fibres. Each of the optical cables 17 extends to a concentrator 12 where the fibres in the cable are split as before to form a number of seismic cables 14 .
A sensor unit 5 that may be employed in the sensor typically comprises three seismic sensors arranged in orthogonal directions and a hydrophone. Each seismic sensor is in the form of a coil of optical fibre wound around a former whose diameter will vary slightly when subjected to seismic vibrations so that the length of the optical fibre coil will also vary. Between the coils of optical fibre are arranged mirrors or other reflection devices such as Bragg gratings, so that a signal sent along the optical fibre will be reflected by each mirror to form a pair of pulses whose separation will depend on the length of the optical fibre winding. Such sensor units comprising three orthogonal seismic sensors and a hydrophone may be referred to as an optical sensing unit (OSU). The sensors may also be connected in other ways well known in the field, for instance in a transmissive coupler configuration
The seismic sensors and hydrophone are fibre optic devices, and the connection cable will comprise a number of optical fibres for connecting the sensors of each sensor unit to its neighbours in the chain. In one embodiment, a continuous length of cable 2 may connect all of the sensor units in a deployment device. The cable may have a number of optical fibre pairs running along its length, and at each sensor unit a single fibre may be drawn out of the cable and connected to the sensors of that sensor unit.
Each optical sensing unit (OSU) will require four channels (one for each seismic sensor and one for the hydrophone) and may be deployed in groups of four, which require 16 optical channels per group. This may conveniently be achieved by time division multiplexing, in which the input optical signal is pulsed and returning optical pulses from different sensors are distinguished by time of flight. Additional multiplexing that is required in order to interrogate all the optical sensing units is achieved by means of wavelength division multiplexing, in which pulses of a number of different wavelengths, typically 16, are sent into the system and each wavelength is routed to a separate set of time multiplexed sensors using commonly known wavelength selective components. The received signals are therefore sent from the optical sensing units to the receiver as a number of time division multiplexed and wavelength division multiplexed streams. The optical signal from each sensor contains the data from that sensor encoded as a phase modulation. Typically, the receiver may receive in the order of 30 different TDM/WDM streams corresponding to 480 channels. An implementation of this architecture is described in European Patent No. EP 1 169 619 B1.
In addition to being deployed on a fixed oil production platform as shown in FIG. 1 , the arrangement may be terminated on a floating production and storage offloading vessel (FPSO) shown schematically in FIG. 4 . This is essentially a vessel 10 having a fixed turret 11 through which the riser cable extends. The vessel is tethered by means of cables 14 , but the vessel may yaw to some extent by virtue of waves, currents and tides, so that the vessel 10 may rotate around the fixed turret 11 . The interrogator 16 is located on the vessel.
FIG. 5 is a schematic diagram showing the principal layout of the arrangement according to the invention. The arrangement comprises an interrogator forming the main part of the diagram which comprises an interrogator hub 20 and a concentrator connected to each other by a riser cable. The interrogator sends signals to a sensor array as shown in FIGS. 2 and 3 , one line 1 of which is shown, and receives, processes and stores return signals from the array. The interrogator comprises a transmitter for sending an optical drive signal to the array comprising a high specification laser source 22 for generating a constant optical signal and an acoustic optical modulator (AOM) 24 (or other suitable optical switch as such an electro-optic switch) for pulsing and frequency shifting the optical signal. Typically the AOM will produce a pair of pulses, one of which is time delayed and frequency shifted by typically 50 KHz with respect to the first pulse, from the transmitter to the array so that a train of pulses is reflected by the mirrors located between the sensor coils of the OSUs within the array. If the time delay of the second pulse corresponds to the time taken for a pulse to travel through one coil between the two mirrors and its return following reflection by the mirror on the far side of the coil, pulses will be generated which are a superposition of initial and time delayed pulses 26 reflected by different mirrors in the array, and this superposed pulse, which is at a difference frequency of typically 50 kHz, carries the phase information from the sensor between those mirrors as a phase modulation of the carrier frequency. The repetition rate of this pulse pair 26 is typically 200 kHz and this may be amplified by means of amplifier 28 . The interrogator may also need to generate a timing or synchronising signal 30 which is sent to the AOM of the transmitter and also to the concentrator. The laser source 22 , AOM 24 and any amplifier 28 that may be present will normally be located on the platform or FPSO within the interrogator hub 20 . The arrangement includes an optical fibre 32 , preferably a single optical fibre, which forms part of the riser cable and extends from the platform or FPSO down to a concentrator located on the seabed in the region of the platform. In the concentrator are typically located a number of splitters, for example a 1:2 splitter 36 , 1:16 splitters 38 for each of the fibres from the splitter 36 and further 1:2 splitters 40 to split the optical fibre 32 into 64 fibres. The fibre may be split into any appropriate number of fibres, but will normally be split into 128 fibres or so. In addition, further amplifiers 42 , 44 may be present The optical signal may be amplified directly by means of an optical amplifier, for example an erbium doped fibre amplifier (EDFA). Any amplifier employed may also be a distributed optical amplifier which amplifies the optical signals continuously along part or the whole of the link between the interrogator and the array 1 .
The array comprises a two dimensional array of optical sensing units (OSUs) formed in each array line, and each sensing unit comprising three orthogonally oriented seismic vibration sensors and one hydrophone, the vibration sensors being typically separated by mirrors so that the delay and hence the phase change of signals reflected by the mirrors will depend on the parameter being detected by the OSUs. The sensors may also be connected in other configurations allowing measurement of individual sensor optical phase change.
After leaving the array the fibres return to the concentrator. Only a single fibre 50 is shown leaving the array line 1 for the sake of clarity as indeed only a single fibre 46 is shown entering the array, but as indicated above, typically 64 to 128 fibres will be employed. After leaving the array, the signals may be amplified by a further amplifier 52 (one for each optical fibre 50 leaving the array) which will typically be located inside the concentrator or may be located outside it if a distributed amplifier is employed. After amplification, the signal is passed to an optical-to-electrical converter typically comprising a detector formed from a p-i-n or avalanche photodiode 54 . The electrical signals so produced are sent to an A/D converter 56 to sample the signals, for example at 200 kHz, and to digitise them, and the digital signals are passed to a phase demodulator 58 . In one implementation, the signals will have a carrier frequency of 50 kHz, which is phase modulated by the seismic signal which will typically be in a frequency range of 5-500 Hz.
After phase demodulation, the signals from the optical fibre 50 together with the signals on all the other optical fibres 52 from the array are multiplexed by means of multiplexer 60 which also receives timing signals sent from the interrogator hub. As an alternative to sending timing signals directly to the receiver, timing signals sent to the array line by the transmitter may be detected before being sent to the array and then sent to the phase demodulator 58 by fibre 57 . The multiplexed signal is then converted to an optical signal by diode 62 or laser. The multiplexing may be performed electrically or optically or by a mixture of both and the signal on the fibre exiting the submersible module will preferably be wavelength division multiplexed (WDM) especially dense wavelength division multiplexed (DWDM) in which up to 128 signals may for example be carried by a single fibre on the 1550 nm band.
The DWDM signal is then carried by a single optical fibre 64 in the riser cable to the platform or FPSO whereupon it is converted to an electrical signal by means of photodetector 66 and sent to signal processing module 68 where the data is recorded and stored on disc 70 if necessary. Often the signal processing module 68 and disc or other recorder will be located physically close to one another in the same interrogator module or housing, but, as indicated above, the transmitter and receiver of the interrogator may be physically separated by a significant distance. Similarly, it is possible for different parts of the receiver to be separated between the concentrator and the interrogator hub. For example, it is possible for the receiver to include a communications module for packetising the multiplexed signals and sending them along a transmission channel to a recorder 70 as a single data stream, using techniques well known in digital data communications. The communications module may be operative to send the data from the demodulator 58 and multiplexer 60 by any appropriate means, for example by means of a satellite or microwave link, although it will normally be operative to send the data from the demodulator my means of a cable, especially an optical cable. This may be the same cable as the riser cable or a different cable.
For a typical array, the receiver will receive 16 time division multiplexed data streams each of which is converted into an electrical signal using a separate photodiode 54 . These are WDM multiplexed at 16 wavelengths, leading to 256 TDM data streams. The electrical data streams are digitised to generate 256 time domain multiplexed phase modulated outputs by the phase modulator 58 . In a typical heterodyne modulated system, each channel will have a heterodyne carrier frequency of 50 kHz and will be sampled at a sampling frequency of 200 kHz, although many other configurations of phase modulated data are possible. It will be necessary to multiplex the data at a rate sufficiently high to ensure that full bandwidth of the modulated data has been captured, so allowing accurate demodulation of the data. For example, in a typical system a data sample rate of 50 kHz with 32 bits per sample, 16 channels per wavelength and 16 different wavelengths will generate a signal with 0.4Gbits per second for each sensor line. If 64 sensor lines are employed as described above, this gives a total data transmission rate of 26 Gbits per second transmitted along fibre 64 . Clearly other data sample rates, or even data compression techniques may be chosen resulting in a different total data transmission rate.
The arrangement according to the invention thus enables the array 1 to be connected to the main part of the interrogator (the interrogator hub), i.e. those parts of significant size or which involve significant electronic signal processing, by only a small number of optical fibres so that conventional slip rings may be used, or even, depending on the form of packaging of the optical fibres, so that slip rings may be dispensed with and so that any change in direction of the fibre in the system may be accommodated by bending of the fibre. As described above with reference to FIG. 5 , the concentrator may be placed on the sea bed within a waterproof module requiring only a small number of fibre and power connections to the interrogator. The concentrator could include a stowed multi-way riser cable connecting the multiplexing optics and electronics to the array cables.
Such a form of concentrator is shown schematically in FIG. 7 . Here the interrogator is formed as a permanent installation 80 (which is the interrogator hub) on a platform 82 and includes a submersible module 84 (housing the concentrator) that is connected to the permanent installation 80 by the riser cable 9 comprising optical fibres 32 and 64 optionally together any electrical cables. The submersible module will house those parts of the interrogator which are located underwater, typically, the receiver demodulator and multiplexer, and also preferably parts of the transmitter as described above. The total volume of those parts of the interrogator within the submersible module will be of the order of 0.2 cubic meters, significantly smaller than the full interrogator which will have a volume of at least 3 cubic meters. The submersible module may include a reel or other means for stowing the riser cable that is able to collect the riser cable as the module is raised onto the platform 82 and to pay out any other cable if necessary connected to the array in order to accommodate the change in position of the module. Similarly the module may be arranged to pay out the riser cable 9 as it is lowered from the platform to the seabed and to collect any other cable attached to the array. The submersible module would normally be located on the seabed, although it could be used at any position in the water column.
It is possible in other instances to employ a multi-fibre riser cable with one fibre for each sensor unit of the array, and to locate the termination (including the phase demodulator and the multiplexer) on a stationary turret of an FPSO with single fibres directed to the interrogator unit on the main part of the FPSO by means of conventional slip rings. The termination that employs the submersible module could be employed with an FPSO if desired.
It is possible that more than 1 concentrator is used, as shown in FIG. 3 . In this case the individual concentrators 12 are each connected by a transmit optical fibre and a return datalink to the interrogator hub 11 via passive hub 16 which combines the individual transmit fibres and return fibres (if used) into a single riser 6 . Alternatively the concentrators 12 may be connected via a single cable arranged in a loop which connects all the concentrators to the passive hub. The loop may be arranged such that the signals can be transmitted in either direction around the loop
As described with respect to FIG. 5 , the sensor array sends phase modulated optical pulses whose phase modulation amplitude is dependent on the output of the sensors along the fibre 50 to the receiver. However, it is possible for the returned pulses to have too high a phase modulation amplitude and to cause phase based sensed information to become distorted leading to failure of the demodulation process. According to a preferred aspect of the invention, the sensors of the sensor array may be operable to generate derivative signals (that is, signals dependent on the rate of change of phase) instead of, or in addition to, the signals dependent on the amplitude of the phase. For example, this may be achieved as described in WO2008/110780, the disclosure of which is incorporated herein by reference. In this case, since two derivative signals are sent in addition to the phase amplitude signals, there will be approximately three data streams instead of one, and the system will require three times the bandwidth. The derivative return pulses (which are dependent on the rate of change of phase) will have a much lower phase modulation amplitude than the pulses that are dependent on the amplitude of the phase, and so may be used instead of the amplitude return pulses. In this case it is possible for the arrangement to have a much larger dynamic range by relying on high sensitivity amplitude return pulses where required and otherwise to rely on lower sensitivity derivative return pulses.
It is possible to vary the sensitivity of the return signals by varying the time separation of the initial signal and so increase the dynamic range of the system. In addition, as described in WO2010/023434, the disclosure of which is also incorporated herein by reference, the optical fibre that returns the signals from the sensors may be split so that light may be sent to two different interferometers that reflect the light along the return optical fibres 50 . One interferometer may have a relatively large path imbalance (say, 20 m or 200 ns) while the other interferometer may have a much smaller path imbalance (say, 1 m) which will be less than the pulse duration and will alter the dynamic value of the signal accordingly. As a result, it is possible for the derivative sensor technique to generate return pulses of a range of sensitivities, from high sensitivity return signals based on the amplitude of the reflected signals to medium and low sensitivity return signals based on the derivative of the phase of the reflected signals.
Although the derivative sensor technique may be used to generate return signals of three different sensitivities, different sensitivity signals for each of the different wavelengths in the WDM return signals may be carried by the same optical fibre. For example, one fibre may be used to carry medium sensitivity return signals (referred to as “long DST” signals, while another fibre may be used to carry full sensitivity and low sensitivity return signals (referred to as “normal” and “short” DST signals respectively.
The two fibres may extend in parallel to one another as shown in FIG. 6 . A single optical fibre 46 transmits the pulses from the transmitter 20 to a number of interferometers 5 in the concentrator which generates three signals, one medium sensitivity DST derivative output (referred to as the long output) on optical fibre 50 ( 1 ) and a full sensitivity amplitude output (referred to as the normal output) and a low sensitivity derivative output (referred to as the short output) that are multiplexed on optical fibre 50 ( 2 ). In this case each of the separate lines are converted into electrical signals, amplified where necessary, digitised with a 200 kHz sample rate, phase demodulated by phase demodulators 58 , and downsampled to a 1 kHz sample rate separately before being multiplexed with each other and with signals from the other OSUs in the array by multiplexer 60 . Timing signals that have been sent from the interrogator hub down the riser cable and received by the multiplexer 60 are sent to the phase demodulators 58 along lines 72 . In this arrangement, the phase delay between a 50 kHz synchronization signal and the incoming data will be computed at a data rate of 50 kHz. Data at approximately 1.5 Gbit s −1 from four array lines received by fibres 50 and 53 of FIG. 5 will be multiplexed by the multiplexer 60 to generate payload of 5.84 Gbit s −1 for each wavelength which can be transported by a 10 Gbit Ethernet line or other transmission protocol. The data from 16 lines is then multiplexed by multiplexer 61 by dense wavelength division multiplexing (DWDM) to allow data from 64 fibre pairs to be multiplexed on a single return fibre. | An arrangement for monitoring a submarine reservoir includes a number of sensor units located in an array on the seabed, and an interrogator unit for obtaining data on the reservoir from the sensor units. The interrogator unit includes a transmitter unit for sending optical signals to the sensor array and a receiver unit for receiving modulated optical signals from the array. Optical radiation from an optical source is transmitted along an uplink optical fiber which is split in a number of positions to form the array. The receiver unit includes optical-to-electrical converters for converting the optical signals to electrical signals, a phase demodulator, a multiplexer, a signal processor, and recording unit. The interrogator unit is divided into a concentrator and an interrogator hub, where signals are transmitted between the interrogator hub and concentrator along a riser cable. This enables the interrogator to be moved between a platform and the seabed. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to repairing damaged surfaces, particularly vehicle body surfaces. One common method for repairing such surfaces is to employ a putty to fill in holes and dents, followed by sanding the putty after it has dried and then painting. One problem with this very common method is that the putty tends to fall out due to vibration or rusting in the area around the putty, or both. Also, once an area of a vehicle begins to rust, adjacent areas tend to rust more quickly and it has done little good to have puttied one particular area.
Fiberglass cloth is sometimes used to repair larger areas, particularly where there are holes. A chemical adhesive is used which must be exposed to sunlight in order to harden. The fiberglass cloth is then coated with a putty, sanded and painted. This system is very difficult to work with and requires a fairly high degree of skill.
Another prior art method involves employing a piece of metal foil which is adhered to the surface to be repaired with an adhesive. It is difficult to insure that the foil will be smooth and this method is practical only over very small areas.
Sheet metal is sometimes used to repair large areas. It is difficult to secure the sheet metal to the vehicle body, with sheet metal screws usually being necessary and being difficult to conceal. Even then, the sheet metal must often be puttied over since it does not conform particularly well to the surface being repaired. If the sheet metal is bare, it has to be treated with acid prior to painting.
All in all, the processes available are quite difficult to use and are costly when done by a professional and not particularly good looking when done by an amateur.
SUMMARY OF THE INVENTION
The present invention employs a method and articles wherein a sheet of plastic is used to cover the area to be repaired after the area has been made reasonably smooth and free of excessive flaking rust. The sheet of plastic is sufficiently pliable that it can be manually shaped to conform generally to the area to be repaired, but is sufficiently rigid that it resists oil canning, denting and other localized deformation. One manually shapes the plastic to conform generally to the area to be repaired and the edges of the sheet are beveled so that they blend into the vehicle surface. The sheet is adhered to the vehicle area with an adhesive and the entire repaired area is painted over.
Preferably, a sealant is employed at least along the visible edges of the plastic sheet. This sealant is of a material which dries firm, but resilient, whereby cracking is minimized. The sealant is applied to the edges and feathered out onto the body surface so as to create a smooth flowing surface overall.
The result is a process which is relatively inexpensive to perform and which can be done by an amateur to create a reasonably good looking repaired surface. These and other objects, advantages and features of the invention will be more fully understood and appreciated by reference to the written specification and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary view of an automobile whose front rocker panel has been repaired in accordance with the method of the present invention;
FIG. 2 is a fragmentary view showing a sheet of plastic in accordance with the present invention spaced from an area which has to be repaired;
FIG. 3 is a cross sectional view taken along plane III--III of FIG. 1;
FIG. 4 is a flow diagram illustrating the steps employed in accordance with the method of the present invention; and
FIG. 5 is a front elevational view of a kit in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the preferred embodiment, the rusted area 10 (FIG. 2) of the vehicle 1 (FIG. 1) is covered with a plastic sheet 20 which is held in place by means of a contact adhesive 30 (FIG. 3). The beveled edges 21 of the plastic sheet 20 are sealed by the application of an edge sealant 40 which is feathered out from the plastic sheet onto the surface of the vehicle to create a smooth appearance. The materials necessary to practice this method can be provided in kit form as shown in FIG. 5 wherein a plastic kit container 50 contains a plastic sheet 20, a contact adhesive 30 and a sealant 40.
The plastic sheet 20 is preferably a sheet of polyvinyl chloride material. Polyvinyl chloride is reasonably resistant to solvent attack from most commercial contact cements and has a surface to which paint, either lacquer or enamel, adheres.
The particular sheet plastic employed must not be brittle. It has been found that the type of polyvinyl chloride sheet used as a house or building siding works very well in practicing the present invention.
Plastic sheet 20 must have sufficient pliability that it can be manually shaped to conform generally to the area to be repaired. Yet, it must be sufficiently rigid to resist oil canning, denting and other localized deformations. It has been found that for areas where there is a sharp bend on the vehicle body, or for small repair jobs, a sheet of polyvinyl cloride about 20 mils thick is best. For larger areas, and for areas where no sharp bends are required, a sheet of polyvinyl chloride having a thickness of approximately 40 mils is best. The thicker sheet is particularly good where it is being applied over a large opening in the metal or plastic body of the car since the 40 mil thick sheet gives greater rigidity to the final repair job.
The adhesive 30 which is employed to adhere plastic sheet 20 to the area 10 to be repaired is preferably a contact cement. It is applied to the area 10 to be repaired and to the rear surface of plastic sheet 20. The rear surface of plastic sheet 20 should be roughened prior to application of the contact cement. This can be accomplished by sanding just prior to application of the contact cement. In the alternative, a plastic sheet having a molded-in roughened rear surface can be employed. Most contact cements commonly available on the market can be employed. For safety purposes, it is peferable to employ a non-flamable contact cement. One commercially available product called "Con-Bond" (TM) is available from Columbia Cement Company of Freeport, N.Y., and works very well in practicing the invention.
The edge sealant 40 employed must be of a material which dries firm, but remains resilient. This is to prevent cracking which might otherwise occur with vehicle vibration. A caulking which would dry hard would not be satisfactory since it would eventually crack and flake out. A silicon tub caulking works very well as sealant 40. Dow Chemical makes such a product and another sealant which works exceptionally well is "Flexible Kwik Seal Tub and Tile Caulk" (TM) marketed by DAP, Inc.
The first step in practicing the method is to determine the area of the vehicle body to be repaired (FIG. 4). One must then cut the plastic sheet 20 to match the desired area of the vehicle body to be covered. If possible, the plastic sheet 20 should be cut so that its edge comes up to a sharp bend or to a molding strip or to some other deviation in the body surface so that the edge of the plastic sheet 20 is not readily apparent in the final repair job.
The area 10 to be repaired should be prepared so that it is reasonably smooth and reasonably free of peeling, flaking rust. A loose chunk of rust between the plastic sheet 20 and the surface being repaired could create a bulge in plastic sheet 20. While the preparation need not be as extensive as is normally the case in auto body repair techniques, some preliminary precautions should be taken.
The edges of the plastic sheet are then beveled by the use of a razor knife or the like. This results in beveled edges 21 as shown in FIG. 3. In the alternative, the kit 50 could include plastic sheet with pre-beveled edges.
The adhesive 30 is then applied to the roughened back side of plastic sheet 20 and to the vehicle body area 10 to be repaired. As is common for contact adhesives, it should be applied at room temperature. If working in a colder area, a torch or other heating implement can be used to heat up the areas prior to application of the cement.
After the cement has had an opportunity to tackify, as is common practice with contact cements, the plastic sheet 20 is applied to the vehicle body over the area 10 to be repaired. The edges of the vinyl plastic sheet are then further sanded and any excess adhesive which is squeezed out around the edges of plastic sheet 20 is removed. Gasoline or other solvent can be used to remove excess adhesive. Gasoline is also used to wipe the entire surface of the plastic sheet 20 to improve adherence of the paint.
The beveled and sanded edge 21 of plastic sheet 20 is then covered with edge sealant 40. The excess is wiped away and sealant 40 is feathered out so as to create a smooth flowing surface from the exposed surface of plastic sheet 20 out onto the surface of the vehicle around the edges thereof. It is necessary to worry about beveling, sanding and the application of sealant only at edges of plastic sheet 20 which will be readily visible when the vehicle is viewed. Usually, it is not necessary to worry about this along bottom edges of rocker panels and the like where the repair job is rarely seen.
The thus repaired surface is painted in the usual manner. The results as can be seen from FIG. 1 is an attractive repaired surface. This is achieved with a minimum of expense in either terms of material or labor and accordingly constitutes a significant contribution to the art. Of course, it will be understood that alterations and variations can be made without departing from the spirit and broader aspects of the invention as set forth in the appended claims. | The specification discloses a method and a kit for repairing surfaces, particularly vehicle surfaces, in which the surface to be repaired is covered by adhering a plastic sheet having beveled edges thereto, followed by sanding the beveled edges and adhering sealant to at least the visible edges, feathering the sealant so as to create a smooth surface, followed by painting the repaired area. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent Application No. 60/773,197, filed Feb. 14, 2006, the disclosures of which are incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a molecular sieve composition, particularly but not exclusively to a crystalline molecular sieve composition.
BACKGROUND
[0003] Molecular sieve materials, both natural and synthetic, have catalytic properties for various types of hydrocarbon conversion. Certain molecular sieves (e.g., zeolites, AlPOs, and/or mesoporous materials) are ordered, porous crystalline materials having a definite crystalline structure. Within the crystalline molecular sieve material there are a large number of cavities which may be interconnected by a number of channels or pores. These cavities and pores are uniform in size within a specific molecular sieve material. Since the dimensions of these pores are such as to accept for adsorption molecules of certain dimensions while rejecting those of larger dimensions, these materials have come to be known as “molecular sieve” and are utilized in a variety of industrial processes.
[0004] Such molecular sieves, both natural and synthetic, include a wide variety of positive ion-containing crystalline silicates. These silicates can be described as a rigid three-dimensional framework of SiO 4 and Group IIIA element oxide (e.g., AlO 4 ) (as defined in the Periodic Table, IUPAC 1997). The tetrahedra are cross-linked by the sharing of oxygen atoms whereby the ratio of the total Group IIIA element (e.g., aluminum) and silicon atoms to oxygen atoms is 1:2. The electrovalence of the tetrahedra containing the Group IIIA element (e.g., aluminum) is balanced by the inclusion in the crystal of a cation, for example a proton, an alkali metal or an alkaline earth metal cation. This can be expressed as the ratio of the Group IIIA element (e.g., aluminum) to the number of various cations, such as H+, Ca 2+ /2, Sr 2+ /2, Na + , K + , or Li + , is equal to unity.
[0005] Molecular sieves that find application in catalysis include any of the naturally occurring or synthetic crystalline molecular sieves. Examples of these sieves include large pore zeolites, intermediate pore size zeolites, and small pore zeolites. These zeolites and their isotypes are described in “Atlas of Zeolite Framework Types”, eds. W. H. Meier, D. H. Olson and Ch. Baerlocher, Elsevier, Fifth Edition, 2001, which is herein incorporated by reference. A large pore zeolite generally has a pore size of at least about 7 Å and includes LTL, VFI, MAZ, FAU, OFF, *BEA, and MOR framework type zeolites (IUPAC Commission of Zeolite Nomenclature). Examples of large pore zeolites include mazzite, offretite, zeolite L, VPI-5, zeolite Y, zeolite X, omega, and Beta. An intermediate pore size zeolite generally has a pore size from about 5 Å to less than about 7 Å and includes, for example, MFI, MEL, EUO, MTT, MFS, AEL, AFO, HEU, FER, MWW, and TON framework type zeolites (IUPAC Commission of Zeolite Nomenclature). Examples of intermediate pore size zeolites include ZSM-5, ZSM-11, ZSM-22, “MCM-22 family material”, silicalite 1, and silicalite 2. A small pore size zeolite has a pore size from about 3 Å to less than about 5.0 Å and includes, for example, CHA, ERI, KFI, LEV, SOD, and LTA framework type zeolites (RIPAC Commission of Zeolite Nomenclature). Examples of small pore zeolites include ZK-4, ZSM-2, SAPO-34, SAPO-35, ZK-14, SAPO-42, ZK-21, ZK-22, ZK-5, ZK-20, zeolite A, chabazite, zeolite T, gmelinite, ALPO-17, and clinoptilolite.
[0006] The term “MCM-22 family material” (or “material of the MCM-22 family” or “molecular sieve of the MCM-22 family”), as used herein, includes one or more of:
(i) molecular sieves made from a common first degree crystalline building block unit cell, which unit cell has the MWW framework topology. (A unit cell is a spatial arrangement of atoms which if tiled in three-dimensional space describes the crystal structure. Such crystal structures are discussed in the “Atlas of Zeolite Framework Types”, Fifth edition, 2001, the entire content of which is incorporated as reference); (ii) molecular sieves made from a common second degree building block, being a 2-dimensional tiling of such MWW framework topology unit cells, forming a monolayer of one unit cell thickness, preferably one c-unit cell thickness; (iii) molecular sieves made from common second degree building blocks, being layers of one or more than one unit cell thickness, wherein the layer of more than one unit cell thickness is made from stacking, packing, or binding at least two monolayers of one unit cell thickness. The stacking of such second degree building blocks can be in a regular fashion, an irregular fashion, a random fashion, or any combination thereof; and (iv) molecular sieves made by any regular or random 2-dimensional or 3-dimensional combination of unit cells having the MWW framework topology.
[0011] The MCM-22 family materials are characterized by having an X-ray diffraction pattern including d-spacing maxima at 12.4±0.25, 3.57±0.07 and 3.42±0.07 Angstroms (either calcined or as-synthesized). The MCM-22 family materials may also be characterized by having an X-ray diffraction pattern including d-spacing maxima at 12.4±0.25, 6.9±0.15, 3.57±0.07 and 3.42±0.07 Angstroms (either calcined or as-synthesized). The X-ray diffraction data used to characterize said molecular sieve are obtained by standard techniques using the K-alpha doublet of copper as the incident radiation and a diffractometer equipped with a scintillation counter and associated computer as the collection system. Materials belonging to the MCM-22 family include MCM-22 (described in U.S. Pat. No. 4,954,325), PSH-3 (described in U.S. Pat. No. 4,439,409), SSZ-25 (described in U.S. Pat. No. 4,826,667), ERB-1 (described in European Patent No. 0293032), ITQ-1 (described in U.S. Pat. No. 6,077,498), ITQ-2 (described in International Patent Publication No. WO97/17290), ITQ-30 (described in International Patent Publication No. WO2005118476), MCM-36 (described in U.S. Pat. No. 5,250,277), MCM-49 (described in U.S. Pat. No. 5,236,575) and MCM-56 (described in U.S. Pat. No. 5,362,697). The entire contents of the aforesaid patents are incorporated herein by reference.
[0012] It is to be appreciated the MCM-22 family molecular sieves described above are distinguished from conventional large pore zeolite alkylation catalysts, such as mordenite, in that the MCM-22 materials have 12-ring surface pockets which do not communicate with the 10-ring internal pore system of the molecular sieve.
[0013] The zeolitic materials designated by the IZA-SC as being of the MWW topology are multi-layered materials which have two pore systems arising from the presence of both 10 and 12 membered rings. The Atlas of Zeolite Framework Types classes five differently named materials as having this same topology: MCM-22, ERB-1, ITQ-1, PSH-3, and SSZ-25.
[0014] The MCM-22 family molecular sieves have been found to be useful in a variety of hydrocarbon conversion processes. Examples of MCM-22 family molecular sieve are MCM-22, MCM-49, MCM-56, ITQ-1, PSH-3, SSZ-25, and ERB-1. Such molecular sieves are useful for alkylation of aromatic compounds. For example, U.S. Pat. No. 6,936,744 discloses a process for producing a monoalkylated aromatic compound, particularly cumene, comprising the step of contacting a polyalkylated aromatic compound with an alkylatable aromatic compound under at least partial liquid phase conditions and in the presence of a transalkylation catalyst to produce the monoalkylated aromatic compound, wherein the transalkylation catalyst comprises a mixture of at least two different crystalline molecular sieves, wherein each of said molecular sieves is selected from zeolite beta, zeolite Y, mordenite and a material having an X-ray diffraction pattern including d-spacing maxima at 12.4±0.25, 6.9±0.15, 3.57±0.07 and 3.42±0.07 Angstrom (Å).
[0015] The MCM-22 family molecular sieves including MCM-22, MCM-49, and MCM-56 have various applications in hydrocarbon conversion processes. Unfortunately, industrial applications of zeolite catalysts have been hindered due to some major disadvantages associated with the current synthesis techniques that make large scale production of these catalysts complicated and therefore expensive. At present, crystalline zeolite catalysts are synthesized mainly by conventional liquid-phase hydrothermal treatment, including in-situ crystallization and seeding method, and the vapor phase transport method.
[0016] In the hydrothermal method, a reaction mixture of silica, alumina, caustic agent, an organic template or structured directing agent, and water is heated at a high temperature in a liquid phase to produce crystalline zeolite crystals (see also U.S. Pat. No. 5,871,650, Lai et al.) . The main drawbacks of this method are the difficulty in assuring the uniformity of the crystallization conditions and limited reproducibility of high quality membranes.
[0017] In the vapor phase transport method, an extrudate reaction mixture of silica, alumina, caustic agent, an organic template or structure directing agent and water is heated at autogenous pressure at 100° C. in a sealed reactor for a number of days. The extrudate is then dried in a vacuum oven overnight and calcined in air at a high temperature for a further eight hours to produce a crystalline zeolite (see also U.S. Pat. No. 5,558,851, Sep. 24, 1996, Miller). This method is unsuitable for producing crystalline zeolite on a large scale as the process is complicated and it takes a long time. In addition, the resulting crystalline zeolite has low crush strength and lacks uniformity and consequently has poor quality.
[0018] The present invention aims to obviate or at least mitigate the above described problems and/or to provide improvements generally.
SUMMARY OF THE INVENTION
[0019] According to an embodiment of the invention, there is provided a molecular sieve composition as defined in any of the accompanying claims.
[0020] In an embodiment of the invention there is provided a crystalline molecular sieve composition obtainable by
(a) crystallizing a pre-formed extrudate mixture in a reactor, the pre-formed extrudate mixture comprising at least one source of ions of tetravalent element Y, at least one source of alkali metal hydroxide, water, optionally at least one seed crystal, and optionally at least one source of ions of trivalent element X, said reaction mixture having the following mole composition:
[0000] Y:X 2 =10 to infinity (a)
[0000] OH − :Y=0.001 to 2 (b)
[0000] M + :Y=0.001 to 2 (c)
[0000] wherein M is an alkali metal and the amount of water is at least sufficient to permit extrusion of said reaction mixture; and
b) during crystallization, removing excess alkali metal hydroxide from the pre-formed extrudate.
[0023] During crystallization, the level of alkali metal hydroxide required for the reaction is present at all times as superfluous alkali metal hydroxide is removed. In this way the critical level of alkali metal hydroxide is maintained uniformly in the pre-formed extrudate mixture. The removal of excess alkali metal hydroxide results in the formation of a good quality sieve in-situ extrudate which has a uniform crystalline structure.
[0024] In an embodiment, the element Y ion source in the reaction mixture, eg silica where Y is silicon, acts as a binder to bind the reaction components after extrusion and prior to crystallization so that the pre-formed extrudate retains its structure during crystallization. Furthermore, since the reaction mixture is extruded prior to crystallization the crystalline sieve structure/morphology is not damaged in any way by a part-crystallization extrusion step which would otherwise affect its mechanical properties. This is a problem in sieves produced in conventional processes.
[0025] The sources of the various elements required in the final product may be any of those in commercial use or described in the literature, as may the method of preparation of the synthesis mixture.
[0026] The crystalline molecular sieves of the invention are obtainable by a method employing a preformed extrudate in which the tetravalent element is provided as an oxide. Preferably, the source of the oxide of the tetravalent element, YO 2 , comprises solid YO 2 , preferably about 30 wt. % solid YO 2 in order to obtain the crystal product of this invention. When YO 2 is silica, the use of a silica source containing preferably about 30 wt. % solid silica, e.g., silica sold by Degussa under the trade names Aerosil or Ultrasil (a precipitated, spray dried silica containing about 90 wt. % silica), an aqueous colloidal suspension of silica, for example one sold by Grace Davison under the trade name Ludox, or HiSil (a precipitated hydrated SiO 2 containing about 87 wt. % silica, about 6 wt. % free H 2 O and about 4.5 wt. % bound H 2 O of hydration and having a particle size of about 0.02 micro) favors crystal formation from the above mixture. Preferably, therefore, the YO 2 , e.g., silica, source contains about 30 wt. % solid YO 2 , e.g., silica, and more preferably about 40 wt. % solid YO 2 , e.g., silica. The source of silicon may also be a silicate, e.g., an alkali metal silicate, or a tetraalkyl orthosilicate. Alternative tetravalent elements may be germanium, titanium and tin. The reaction mixture may contain a source of ions of a single tetravalent element such as silicon or two or more tetravalent elements, eg silicon and germanium.
[0027] The source of the ions of the trivalent element, X, when present, is preferably the oxide X 2 O 3 . For example, the trivalent element may be aluminum, and the ion (oxide) source is preferably aluminum sulphate or hydrated alumina. Other aluminum sources include, for example, other water-soluble aluminum salts, sodium aluminate, or an alkoxide, e.g., aluminum isopropoxide, or aluminum metal, e.g., in the form of chips.
[0028] The alkali metal of the hydroxide is advantageously potassium or sodium, the sodium source advantageously being sodium hydroxide or sodium aluminate. The alkali metal oxide solution may also comprise a caustic agent, preferably sodium hydroxide.
[0029] In a preferred embodiment, the crystallization is carried out in the presence of a structure directing agent R. Thus in one embodiment, the reaction mixture additionally comprises R, such that the preformed extrudate comprises a structure directing agent R. In another embodiment, the structure directing agent R is made available to the crystallization reaction by being contained in the reactor but not in the pre-formed extrudate. In yet another embodiment, the structure directing agent may form part of the reaction mixture used to form the pre-formed extrudate, and a further amount of structure directing agent R, may be provided in the reactor separate from the pre-formed extrudate.
[0030] Directing agent R is preferably selected from the group consisting of cycloalkylamine, azacycloalkane, diazacycloalkane, and mixtures thereof, with alkyl preferably comprising from 5 to 8 carbon atoms. Non-limiting examples of R include cyclopentylamine, cyclohexylamine, cycloheptylamine, hexamethyleneimine (HMI), heptamethyleneimine, homopiperazine, and combinations thereof.
[0031] The amount of the directing agent affects the cost and the product quality of the synthesis of a crystalline molecular sieve. The directing agent is generally the most expensive reactant(s) in the hydrothermal reaction mixture of many crystalline molecular sieves. The lower the amount of the directing agent in the hydrothermal reaction mixture, the cheaper the final molecular sieve produced. The term “low directing agent” as used herein means the molar ratio of the directing agent over the tetravalent element in the hydrothermal reaction mixture is less than 0.5, preferably less than 0.34, even more preferably less than 0.2, and most preferably less than 0.15.
[0032] In one embodiment of this invention, R:SiO 2 molar ratio ranges from 0.001 to 0.34, preferably from 0.001 to 0.3, more preferably from 0.001 to 0.25, even more preferably from 0.001 to 0.2, and most preferably from 0.1 to 0.15.
[0033] The composition of the pre-formed extrudates and reaction parameters are critical for producing the high quality and homogeneous phase product of the invention. In preferred embodiments, the Y:X 2 ratio may be 50 to 5000 and/or the water:Y ratio may be 0.5 to 5, and/or the OH − :Y ratio may be 0.1 to 1 and/or the M + :Y ratio may be 0.01 to 2 and/or the R:Y ratio may be 0.01 to 2.
[0034] The reaction mixture may comprise sufficient water to allow extrusion of the reaction mixture. The reactor may contain a further amount of water such that under the applied vapor phase conditions that water is made available to the crystallizing extrudate.
[0035] Preferably, the preformed extrudate includes seed crystals of the molecular sieve, to facilitate the crystallization reaction. The seeds may be present in a wide range of concentrations, eg from 0.1 to 40 wt % of the extrudate, such as from 0.2 to 5 wt %.
[0036] In another embodiment of the invention, the pre-formed extrudate mixture may be exposed to an autogenous pressure and temperature in the reactor which allow crystallization of the mixture under vapor phase conditions. Suitable pressures may be in the range, for example, of from 345 kpag (50 psig) to 6.9 MPag (1000 psig), preferably from 550 kpag (80 psig) to 3.95 MPag (500 psig), and more preferably 690 kpag (100 psig) to 2.07 MPag (300 psig). Suitable temperatures may vary from 50° C. to 500° C., preferably from 80° C. to 250° C., more preferably from 100° C. to 250° C. The reactor may comprise an autoclave or any other suitable chamber in which controlled pressure and elevated temperature conditions for promoting crystallization can be provided.
[0037] In another preferred embodiment the composition of the invention is obtained by a method in which, the pre-formed extrudate is provided on a support within the reactor, the support being adapted to allow removal of the excess alkali metal hydroxide eg caustic solution during crystallization. The support spaces the extrudate from the reactor wall. The support may also promote heat circulation during crystallization of the synthesized mixture. As the support enables removal of the excess alkali metal hydroxide eg caustic during crystallization, a critical level of alkali metal hydroxide eg caustic in the extruded mixture is maintained uniformly which will result in the formation of good quality zeolite in-situ extrudate. The support may comprise one or more aperatures to facilitate separation of leached alkali metal hydroxide eg caustic from the extrudate. The apertures also promote heat exchange between the extrudate and the reactor.
[0038] To date it has been known that molecular sieves may be prepared by a method called in-situ extrudate technique. This process involves formation of an extrudate followed by crystallization in an autoclave. We have discovered that in the prior art preparation technique, leached caustic solution from the pre-formed extrudate reacts with portions of the extrudate which are in contact with the caustic solution. This results in a poor, non-uniform product having poor mechanical properties and in particular having a low crush strength in comparison to zeolites which are synthesized via conventional hydrothermal treatments. In the present invention, separation of the pre-formed extrudate from the excess alkali metal hydroxide solution or excess caustic, for example by bearing the pre-formed extrudate on a support in the reactor, which results in a higher quality crystalline extrudate product, thereby overcoming a longstanding problem in molecular sieve (zeolite) catalyst crystals which are produced by means of conventional vapor phase crystallization processes.
[0039] In addition, removal of the alkali metal hydroxide caustic material during crystallization in turn enhances the vaporized atmosphere which further promotes the vapor phase crystallization. The support thus improves the vapor phase conditions and prevents the crystalline structure from being compromised by the inadvertent presence of unnecessary caustic within the zeolite crystalline structure during crystallization.
[0040] In another embodiment of the invention, the composition may comprise molecular sieve materials such as ZSM-5, ZSM-11, ZSM-12, ZSM-35, ZSM-48, Y and in particular, MCM-22 family molecular sieves. The MCM-22 family sieves may comprise MCM-22, MCM-49 and MCM-56.
[0041] In a further embodiment, the pre-formed extrudate additionally comprises an already synthesized further molecular sieve to form a dual molecular sieve after crystallization. The synthesized further molecular sieve may comprise, for example, zeolite beta, zeolite Y, Mordenite, ZSM-5 or ZSM-12.
[0042] In a preferred embodiment of the invention, the tetravalent element is silicon and the source of ions thereof preferably comprises a source of silica. The trivalent element is preferably aluminum and the source of ions thereof preferably comprises a source of alumina. In a particular embodiment, there is thus provided a composition obtainable by:
(a) providing a reaction mixture of a source of silica, a source of alumina, a caustic agent, water and optionally a seed crystal of a zeolite; (b) extruding said reaction mixture to form a pre-formed extrudate; (c) crystallizing said pre-formed extrudate under vapor phase conditions in a reactor to form said sieve whereby excess caustic agent is removed from the extrudate mixture during crystallization.
[0046] In a further embodiment, combinations of extrudates of the MCM-22 family with an open network structure of interconnected crystals are prepared by crystallizing HMI-containing preformed extrudate reaction mixtures under vapor phase conditions. The mixtures may contain seed crystals for each of the MCM-22, MCM-49, and MCM-56.
[0047] In a preferred embodiment of the invention, the compositions of the pre-formed extrudate for making MCM-22 or MCM-49 or MCM-56 or mixtures thereof may comprise (molar ratios):
[0000] SiO 2 /Al 2 O 3 :10−500; (i)
[0000] OH − /SiO 2 :0.001−0.5; (ii)
[0000] Na/SiO 2 :0.001−0.5; (iii)
[0000] HMI/SiO 2 :0.05−0.5; (iv)
[0000] H 2 O/SiO 2 :1−20; (v) and,
[0048] In the case where seed crystals are present, the seed concentration of the respective MCM-22, MCM-49 or MCM-56 seed crystals is preferably 0.1 to 40 weight % of the extrudate.
[0049] Dual zeolite crystals such as Beta/MCM-22 may be synthesized in a similar fashion. The reaction mixture may comprise silica, alumina, caustic, water, Beta and MCM-22 seed crystals and a structure directing agent. The resulting dual zeolite extrudates comprise a high surface area, high porosity, high crush strength, high activity and intergrown crystal morphology.
[0050] In another embodiment of the invention, the pre-extruded mixture comprises two or more phases of zeolite. In this way, dual zeolite or multiple zeolite catalyst systems can be produced.
[0051] In a further embodiment of the invention there is provided a method for preparing a catalyst comprising activating the molecular sieve as hereinbefore described to form the catalyst. The sieve may be activated for example by water post-treatment of the crystal and/or by surface modification. Suitable surface modification may comprise surface treatment to provide a metal oxide on the catalyst surface such as aluminum oxide.
[0052] In yet another embodiment of the invention, there is provided a catalyst which is formed from a zeolite crystal sieve as herein before described.
[0053] In a further embodiment of the invention, there is provided a catalyst formed from a pre-extruded mixture, said mixture being crystallized under vapor phase conditions whereby excess caustic agent is removed to form a catalyst with low density, high intrusion volume and high crush strength. The catalyst of the invention may also be suitable as a catalyst additive to enhance the performance of existing catalysts.
[0054] By virtue of the removal of excess alkali metal hydroxide during crystallization, the molecular sieves of the present invention and the corresponding catalyst may for example comprise a surface area of at least 300 m 2 /g preferably at least 500 m 2 /g and more preferably at least 600 m 2 /g, as measured by BET surface area analysis using a Tristar 3000 instrument available from Micromeritics Corporation of Norcoss, Ga., USA.
[0055] The crush strength values as reported herein are measured according to the Mobil Test using an anvil/strike plate instrument by determining the resistance of formed molecular sieve extrudate to compressive force. The measurement is performed on cylindrical extrudate having a length to diameter ratio of at least 1:1 and a length greater than ⅛″ (0.32 cm). The determination is performed by placing the extrudate sample between the driven anvil and the fixed strike plate of an instrument comprising a Willrich Test Stand in combination with an Ametek Electronic Force Guage. The Test Stand comprises a movement that holds the Force Guage, and a strike plate. The strike plate is considerably larger than the anvil, and during testing carries the extrudate pellet under test. The anvil portion of the instrument comprises a rectangular ⅛″×½″ (0.32 cm×1.27 cm) anvil surface arranged to apply compressive force to the pellet carried on the strike plate during the testing procedure. Prior to performing the test the minimum gap between opposed surfaces of the anvil and strike plate is about half the diameter of the cylindrical extrudate pellet.
[0056] The sample is prepared by placing the extrudate pellet in a crucible and drying at 121° C. (250° F.) for at least 1 hour. This step may be eliminated if the sample has been previously dried or calcined. Thereafter, the crucible containing the sample is placed on a crucible tray which is transferred to a muffle furnace at 538° C. (1000° F.) for 1 hour. Drying temperature/time may be altered as appropriate for the material under evaluation. However, consistency in treatment and drying between samples is imperative. All samples being compared for a given project or family should be evaluated after pretreatment at the same temperature/time. After such heating the crucible is removed from the furnace and sealed in a desiccator until cool.
[0057] For crush strength determination of a particular molecular sieve product, a representative sample of typically 25 cylindrical extrudate pellets is tested. Such pellets, once cooled in the desiccator, are placed in a buchner funnel under nitrogen flow. For testing a pellet is removed from the funnel using tweezers and placed on the strike plate directly under the raised anvil in a configuration such that the longitudinal axis of the cylindrical pellet is at 90° to the longitudinal axis of the ⅛″×½″ (0.32 cm×1.27 cm) anvil shoe; with the pellet extending entirely across the ⅛″ (0.32 cm) width of the anvil shoe. In this configuration, when under test, the anvil subjects a ⅛″ (0.32 cm) longitudinal portion of the cylinder wall to the applied compression force. Once the pellet is in the required configuration, the instrument is activated such that the anvil is lowered in controlled fashion to apply gradually increasing force to a ⅛″ (0.32 cm) contact area along the “spine” of the pellet until the pellet is crushed. The force reading displayed on the instrument guage at the point of collapse of the pellet is recorded. This technique is repeated for the 25 pellets of the sample, and the average measured crush strength value for the molecular sieve over the 25 readings is calculated. This crush strength is reported in normalized fashion as the average applied force per unit length along the spine of the extrudate to which the anvil sole is applied. Since the anvil dimension is ⅛″ (0.32 cm) the crush strength is reported as force units (lb, kg) per length unit (inch, cm). Thus, if the measured force is, say, 2 lbs (0.91 kg) over the ⅛″ (0.32 cm) width of the anvil, the crush strength would be reported as 16 lb/inch (2.84 kg/cm). As mentioned, the important feature of this test method is the comparative crush strength values obtained for different molecular sieves.
[0058] Preferably the molecular sieve compositions of the invention have crush strength measured by the above-described Mobil Test of at least 5.4 kg/cm (30 lb/inch), more preferably at least 7.2 kg/cm (40 lb/inch) and most preferably at least 9.8 kg/cm (55 lb/inch). This crush strength is advantageously higher than the crush strength of conventionally produced molecular sieve compositions.
[0059] In a further embodiment, the composition may comprise a bulk density of less than 1 g/cc (measured in accordance with ASTM D4284). The composition may also comprise an intrusion volume of greater than 1 ml/g (measured in accordance with ASTM D4284 Standard Test Method for Determining Pore Volume Distribution of Catalyst by Mercury Intrusion Porosimetry).
[0060] According to another embodiment of the invention there is provided an organic compound eg (hydrocarbon) conversion process comprising contacting an organic eg hydrocarbon feedstock with a catalyst or catalyst additive as hereinbefore described under conversion conditions to convert the feedstock to converted product.
[0061] The catalyst compositions of present invention are useful as catalyst in a wide range of processes, including separation processes and hydrocarbon conversion processes. In a preferred embodiment, the catalyst composition of the present invention may be used in processes that co-produce phenol and ketones that proceed through benzene alkylation, followed by formation of the alkylbenzene hydroperoxide and cleavage of the alkylbenzene hydroperoxide into phenol and ketone. In such processes, the catalyst of the present invention is used in the first step, that is, benzene alkylation. Examples of such processes includes processes in which benzene and propylene are converted to phenol and acetone, benzene and C4 olefins are converted to phenol and methyl ethyl ketone, such as those described for example in international application PCT/EP2005/008557, benzene, propylene and C4 olefins are converted to phenol, acetone and methyl ethyl ketone, which, in this case can be followed by conversion of phenol and acetone to bis-phenol-A as described in international application PCT/EP2005/008554, benzene is converted to phenol and cyclohexanone, or benzene and ethylene are converted to phenol and methyl ethyl ketone, as described for example in PCT/EP2005/008551.
[0062] The catalyst composition of the present invention is useful in benzene alkylation reactions where selectivity to the monoalkylbenzene is required. Furthermore, the catalyst of the present invention is particularly useful to produce selectively sec-butylbenzene from benzene and C4 olefin feeds that are rich in linear butenes, as described in international application PCT/EP2005/008557. Preferably, this conversion is carried out by co-feeding benzene and the C4 olefin feed with the catalyst of the present invention, at a temperature of about 60° C. to about 260° C., for example of about 100° C. to 200° C., a pressure of 7000 kPa or less, and a feed weight hourly space velocity (WHSV) based on C4 alkylating agent of from about 0.1 to 50 hour-1 and a molar ratio of benzene to C4 alkylating agent from about 1 to about 50. The catalyst composition of the present invention is also useful catalyst for transalkylations, such as, for example, polyalkylbenzene transalkylations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0063] Embodiments of the invention will now be described by way of example only and with reference to the accompanying drawings in which:
[0064] FIG. 1 presents a diagrammatic cross sectional view of a chamber for crystallizing a molecular sieve synthesis mixture under vapor phase conditions according to one embodiment of the invention, and
[0065] FIG. 2 presents a diagrammatic cross sectional view of a chamber for crystallizing a molecular sieve synthesis mixture under vapor phase conditions to form a crystalline molecular sieve according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0066] In an embodiment of the invention, to prepare the zeolite catalyst, a pre-formed mixture is prepared from the following compounds: silica, alumina, a caustic agent, water, seed crystals and a structure directing agent. Typically, the silica and alumina ratios define the type of zeolite crystal that can be produced. Various examples are described herein below but generally, the silica/alumina ratio is between 10 and infinite. The caustic agent is preferably sodium hydroxide although potassium ions can also be used. The structure directing agent is typically HMI for making in-situ extrudate with a structure type of MWW although other structure directing agents or templates may be used.
[0067] Now turning to FIG. 1 , the mixture is extruded by means of a conventional extruder such as a 5.08 cm (2 inch) Bonnot extruder and the extruded mixture ( 10 ) is provided on a support ( 12 ) for location inside an autoclave chamber ( 14 ). The pre-formed extruded mixture ( 10 ) is subsequently crystallized under vapor phase conditions to form the zeolite crystal catalyst whereby the excess caustic agent is removed from the crystallized material during crystallization. As the support ( 12 ) separates the mixture from the floor of the chamber, this promotes removal of the excess caustic agent and enhances heat circulation and promotes exposure of the mixture to the vapor phase.
[0068] In FIG. 2 , the mixture ( 20 ) is located on a different support ( 22 ) which spaces the mixture from the perimeter or surrounding walls ( 26 ) of the autoclave chamber ( 24 ). This arrangement further enhances the removal of the caustic agent and enhances heat circulation and promotes exposure of the mixture to the vapor phase. This in turn increases the crush strength and the silica/alumina ratio as will be evident from the below Examples 1 and 2.
[0069] Embodiments of the invention will now be described in the following Examples to further illustrate the invention.
Preparation of MCM-22 Pre-Formed Extrudate Mixture
[0070] Extrudates for MCM-22 vapor phase in-situ crystallization were prepared from a mixture of 908 g of Ultrasil Non-PM silica, 330 g of HMI, 180 g of sodium aluminate solution (45%), and 104 g of 50% sodium hydroxide solution, 950 g of de-ionised (DI) water, and 40 g of MCM-22 seed crystals. The mixture had the following molar composition:
[0000] SiO 2 /Al 2 O 3 =29.4 (i)
[0000] H 2 O/SiO 2 =4.54 (ii)
[0000] OH − /SiO 2 =0.17 (iii)
[0000] Na + /SiO 2 =0.17 (iv)
[0000] HMI/SiO 2 =0.23 (v)
[0071] The mixture was mulled and formed into a 0.16 cm ( 1/16″) diameter cylinder extrudate using a 5.08 cm (2″) Bonnot extruder. The extrudates were then stored in a sealed container before use in the below Examples 1 and 2.
EXAMPLE 1
[0072] A 750 g sample of the above-formed wet pre-formed extrudate was placed in a 2-liter autoclave with wire mesh support as shown in FIG. 1 . The mesh size of the support was 2 mm. The distance between bottom of autoclave and wire mesh support is >1.25 cm (½″).
[0073] The extrudate was crystallized at 160° C. (320° F.) for 96 hrs. After the reaction the product was discharged, washed with water and dried at 120° C. (250° F.) , the XRD pattern of the synthesized material showed the typical pure phase of MCM-22 topology. Scanning Electron Microscopy (SEM) analysis showed that the material is composed of agglomerates of platelet crystals (with a crystal size of about 1 microns). The synthesized extrudate was pre-calcined in nitrogen at 482° C. (900° F.) for 3 hrs and was then converted into the hydrogen form by three ion exchanges with ammonium nitrate solution at room temperature, followed by drying at 120° C. (250° F.) and calcination at 540° C. (1000° F.) for 6 hours. The resulting extrudate crystals have a SiO 2 /Al 2 O 3 molar ratio of 24.1, surface area of about 680 m2/g, crush strength of 11.3 kg/cm (63 lb/inch), particle density of 0.432 g/cc, bulk density of about 0.25 g/cc (ASTM D4284), intrusion volume of 1.72 ml/g (measured in accordance with ASTM D4284 Standard Test Method for Determining Pore Volume Distribution of Catalyst by Mercury Intrusion Porosimetry).
EXAMPLE 2
[0074] A 500 g sample of the wet pre-formed extrudate produced as described in Example 1 was placed in a 2-liter autoclave with wire mesh holder as shown in FIG. 2 . The mesh holder separates the sample from the bottom of autoclave and side walls by a distance of greater than 1.25 cm (½″).
[0075] The extrudate was crystallized at 160° C. (320° F.) for 96 hrs. After the reaction the product was discharged, washed with water and dried at 120° C. (250° F.). The XRD pattern of the synthesized material again showed the typical pure phase of MCM-22 topology. The SEM showed that the material is composed of agglomerates of platelet crystals (with a crystal size of about 0.5 microns). The crush strength of the synthesized sample was measured at 12.35 kg/cm (69 lb/inch) which is higher than the crystal in Example 1. The extrudate was pre-calcined in nitrogen at 482° C. (900° F.) for 3 hrs and then was converted into the hydrogen form by three ion exchanges with ammonium nitrate solution at room temperature, followed by drying at 120° C. (250° F.) and calcination at 540° C. (1000° F.) for 6 hours. The resulting extrudate crystals have a SiO 2 /Al 2 O 3 molar ratio of 24.2.
Preparation of MCM-22 Pre-formed HMI-Free Extrudate Mixture
[0076] Aluminosilicate pre-formed extrudates for MCM-22 vapor phase in-situ crystallization were prepared from a mixture of 908 g of Ultrasil Non-PM silica, 180 g of sodium aluminate solution (45%), and 104 g of 50% sodium hydroxide solution, 1080 g of DI water, and 40 g of MCM-22 seed crystals. The mixture had the following molar composition:
[0000] SiO 2 /Al 2 O 3 =29.4 (i)
[0000] H 2 O/SiO 2 =4.54 (ii)
[0000] OH − /SiO 2 =0.17 (iii)
[0000] Na + /SiO 2 =0.17 (iv)
[0077] No HMI was present in the mixture. The mixture was mulled and formed into a 0.16 cm ( 1/16″) diameter cylinder extrudate using a 5.08 cm (2″) Bonnot extruder. The extrudates were then stored in a sealed container before use. Dried extrudates were prepared separately by drying the wet extrudates in an oven at 120° C. (250° F.) for 2 hours. These extrudates were then used in below Examples 3 and 4.
EXAMPLE 3
[0078] The wet extrudates were placed in a 2-liter autoclave with wire mesh support as shown below. The distance between the bottom of the autoclave and the wire mesh support was greater than 1.25 cm (½″). A mixture of 300 g of DI water and 200 g of HMI was added to the bottom of the autoclave. The extrudates were crystallized at 160° C. (320° F.) for 120 hrs. After the reaction, the product was discharged, washed with water, and dried at 120° C. (250° F.). XRD patterns of the as-synthesized and calcined materials showed the typical pure phase of MCM-22 topology identical to the topology of the MCM-22 as prepared in the presence of HMI. SEMs of the as-synthesized material showed that the material was composed of agglomerates of platelet crystals with a crystal size of about 1-2 microns. The resulting dried extrudate had a SiO 2 /Al 2 O 3 molar ratio of 22.2 and crush strength of 3.6 kg/cm (20 lb/inch). Calcined extrudate had a surface area of 640 m 2 /g, bulk density of 0.41 g/ml, and a total intrusion volume of 1.75 ml/g (measured in accordance with ASTM D4284 Standard Test Method for Determining Pore Volume Distribution of Catalyst by Mercury Intrusion Porosimetry).
EXAMPLE 4
[0079] The dried extrudates were placed in a 2-liter autoclave with wire mesh support located near the bottom of the autoclave so that the distance between bottom of autoclave and wire mesh support is >1.25 cm (½″). A mixture of 200 g DI water and 200 g of HMI was added to the bottom of the autoclave. The extrudates were crystallized at 160° C. (320° F.) for 132 hrs. After the reaction, the product was discharged, washed with water, and dried at 120° C. (250° F.). The XRD pattern of the as-synthesized material showed the typical pure phase of MCM-22 topology. The SEM of the as-synthesized material showed that the material was composed of agglomerates of platelet crystals (with an crystal size of about 1-2 microns). The resulting dried extrudate had a SiO 2 /Al 2 O 3 molar ratio of 25.4 and crush strength of 7.5 kg/cm (42 lb/inch). Calcined extrudate had a surface area of 540 m2/g, a bulk density (measured in accordance with ASTM D4284) of 0.6 g/ml, and a total intrusion volume (measured in accordance with ASTM D4284) of 1.07 ml/g.
Preparation of MCM-49 Pre-Formed Extrudate Mixture
[0080] Extrudates for MCM-49 vapor phase in-situ crystallization were prepared from a mixture of 908 g of Ultrasil Non-PM silica, 348 g of HMI, 262 g of sodium aluminate solution (45%), and 36 g of 50% sodium hydroxide solution, 576 g of DI water, and 40 g of MCM-49 seed crystals. The mixture had the following molar
[0000] composition:
[0000] SiO2/Al 2 O 3 =20.8 (i)
[0000] H2O/SiO 2 =3.11 (ii)
[0000] OH−/SiO 2 =0.15 (iii)
[0000] Na+/SiO 2 =0.15 (iv)
[0000] HMI/SiO 2 =0.24 (v)
[0081] The mixture was mulled and formed into 0.16 cm ( 1/16″) cylinder extrudates using a 5.08 cm (2″) diameter Bonnot extruder. The extrudates were then stored in a sealed container before use in Examples 5 and 6.
EXAMPLE 5
[0082] A 300 g sample of the above formed wet extrudate was loaded in a 600 ml autoclave without providing a support so that the mixture was in direct contact with the autoclave walls.
[0083] The extrudate was crystallized at 160° C. (320° F.) for 96 hrs. After the reaction the product was discharged, washed with water and dried at 120° C. (250° F.). A significant amount of clumps of extrudates or loose powder were found at the bottom of the autoclave. The XRD patterns of the synthesized MCM-49 material collected from the top showed a poor crystalline phase of MCM-49 topology, and clump materials collected from the bottom shows MCM-49 and impurity phase of ZSM-35. Continuing the crystallization for 24-48 hrs produced a product with more ZSM-35 impurity. The SEM of the “good quality” MCM-49 synthesized material showed that the material is composed of agglomerates of intergrown platelet crystals (with a crystal size of about 1 micron). The resulting extrudate crystals have a SiO2/Al2O3 molar ratio of 18.
EXAMPLE 6
[0084] A 600 g sample of the pre-formed wet extrudate was placed in a 2-liter autoclave with wire mesh support as shown in FIG. 1 . The distance between bottom of autoclave and wire mesh support is >1.25 cm (½″). 100 g of DI water was added to the bottom of the autoclave.
[0085] The extrudate was crystallized at 160° C. (320° F.) for 120 hrs. After the reaction the product was discharged, washed with water and dried at 120° C. (250° F.). Only small amount of clumps of the extrudate or loose powder was found at the bottom of the autoclave. The XRD pattern of the as-synthesized material showed the highly crystalline of MCM-49 topology. The SEM of the as-synthesized material shows that the material is composed of agglomerates of platelet crystals (with a crystal size of about 1 microns). The supported method appears to be an effective procedure for producing more homogenous and better quality product as compared to above Example 3. Crush strength of the dried extrudate was measured at 8.4 kg/cm (47 lb/inch). The as-synthesized extrudates were pre-calcined in nitrogen at 482° C. (900° F.) for 3 hrs and then were converted into the hydrogen form by three ion exchanges with ammonium nitrate solution at room temperature, followed by drying at 120° C. (250° F.) and calcination at 540° C. (1000° F.) for 6 hours. The resulting extrudate crystals have a SiO2/Al2O3 molar ratio of 17.2, surface area of approximately 620 m 2 /g.
Preparation of Beta/MCM-22 Pre-Formed Extrudate Mixture
[0086] Beta containing pre-formed extrudates were prepared from a mixture of 908 g of Ultrasil Non-PM silica, 500 g of beta crystal, 330 g of HMI, 180 g of sodium aluminate solution (45%), and 104 g of 50% sodium hydroxide solution, 1200 g of distilled water and 40 g of MCM-22 seed crystals. The mixture had the following molar composition:
[0000] SiO 2 /Al 2 O 3 =30.1 (i)
[0000] H 2 O/SiO 2 =5.7 (ii)
[0000] OH − /SiO 2 =0.17 (iii)
[0000] Na + /SiO 2 =0.17 (iv)
[0000] HMI/SiO 2 =0.24 (v)
[0000] Beta crystal/Ultrasil= 35/65(wt. %) (vi)
[0087] The mixture was mulled and formed into 0.127 cm ( 1/20″) Quad extrudates using a 5.08 cm (2″) Bonnot extruder. The extrudates were then stored in a sealed container before use in Example 7.
EXAMPLE 7
[0088] The pre-formed wet extrudates were placed in a 2-liter autoclave with wire mesh support as shown below. The distance between bottom of autoclave and wire mesh support is greater than 1.25 cm (½″).
[0089] The extrudates were crystallized at 150° C. (300° F.) for 96 hrs. After the reaction, the product was discharged, washed with water, and dried at 120° C. (250° F.). The XRD pattern of the as-synthesized material showed the typical mixed phases of MCM-22 and Beta. The scanning electro microscopy (SEM) of the as-synthesized material showed that the material was composed of agglomerates of MCM-22 platelet crystals (with a crystal size of 1-2 microns) and sphere-like Beta crystals. The SEM showed the cross-section of the resulting product. The as-synthesized extrudates were pre-calcined in nitrogen at 482° C. (900° F.) for 3 hrs and then were converted into the hydrogen form by three ion exchanges with ammonium nitrate solution at room temperature, followed by drying at 120° C. (250° F.) and calcination at 540° C. (1000° F.) for 6 hours.
[0090] The dried extrudate had a crush strength of approximately 14.3 kg/cm (80 lb/inch)and improved to 19.7 kg/cm (110 lb/inch) after calcination at 282° C. (540° F.) . The calcined H-form extrudate crystals had a surface area of 715 m 2 /g, bulk density (measured in accordance with ASTM standard D4284) of 0.51 g/ml, and intrusion volume (measured in accordance with ASTM standard D4284) of 1.35 ml/g.
[0091] The above examples show that both the composition of the pre-formed extrudates and the reaction parameters, including the supporting method, are critical for producing a good quality and more homogeneous phase of products. The additions of HMI and seed crystals in the pre-formed extrudates accelerate the crystallization and promote the formation of the desired MCM-22/49 product, although these compounds can be omitted. The support grid functions to provide better heat circulation inside the reactor to allow separation of the excess caustic liquid from the mixture. This also prevents contamination of the mixture with accumulated caustic at the bottom of the autoclave. This in turn reduces clumps formation resulting from liquid phase reaction of the extrudates.
Evaluation in Cumene Test
Catalyst A: Water Wash Post-Treatment of MCM-22 of Example 1
[0092] A 5 g sample of MCM-22 of Example 1 was mixed with 13 ml of de-ionized water in a beaker. After soaking in water for about one hour, any excess water was drained and the catalyst was then air dried at room temperature until free flowing. It was further dried at 120° C. (250° F.) for about 16 hours. The modified sample was evaluated in an aromatics alkylation unit (Cumene unit) as will be discussed below.
Catalyst B: Surface Modification of Aluminum Oxide of MCM-22 of Example 1
[0093] A quantity of 0.695 g of aluminum nitrate nonahydrate was dissolved in about 14 ml of deionized water. This solution was dispersed evenly into 5 g of MCM-22 produced by conventional means without vapor phase crystallization. The wet mixture was then dried at 120° C. (250° F.) for about 16 hours and then calcined in air at 360° C. (680° F.) for 4 hours. Catalyst B has the same shape as catalyst A.
Catalyst C: Surface Modification of Aluminum Oxide of MCM-22 of Example 1
[0094] A quantity of 0.695 g of aluminum nitrate nonahydrate was dissolved in about 14 ml of deionized water. This solution was dispersed evenly into 5 g of MCM-22 produced conventionally without vapor phase crystallization. The wet extrudate was then dried at 120° C. (250° F.) for about 16 hours and then calcined in air at 360° C. (680° F.) for 4 hours.
Catalyst D: Activation of Beta/MCM-22 of Example 7
[0095] A 5 g sample of the catalyst of Example 7 was dried in an oven at 260° C. (500° F.) for 2 hours, prior to weighing into the catalyst basket.
Evaluation in Cumene Unit of Samples of Catalysts A, B, C and D
[0096] Evaluation was carried out in a 300 ml autoclave reactor. 0.25 g of catalyst was transferred into the catalyst basket, and 6 gram of quartz chip was layer below and above the catalyst bed inside the basket. The catalyst and the basket were then dried in an oven at 260° C. (500° F.) for about 16 hours. This catalyst basket was then transferred into a 300 ml autoclave quickly with minimum exposure to ambient atmosphere. The catalyst was subsequently purged with dry nitrogen for 2 hours at 181° C. (358° F.) inside the reactor to remove air and moisture from the reactor. 156 g of benzene was transferred to the reactor under nitrogen and equilibrated with the catalyst for 1 hour at 130° C. (266° F.). 28 g of propylene was transferred into the reactor under 2.07 MPag (300 psig) of nitrogen pressure.
[0097] The reaction started as soon as propylene was added and a constant pressure of 2.07 MPag (300 psig) nitrogen blanketed the autoclave. The reaction was allowed to run for four hours and propylene was completely consumed during this period. Small samples of liquid were withdrawn from the autoclave at regular interval for analysis of propylene, benzene, cumene, diisopropylbenzene (DIPB), and triisopropylbenzene, using gas chromatography. Catalyst performance was assessed by a kinetic activity rate parameter which is based on the propylene and benzene conversion. For a discussion of the determination of the kinetic rate parameter, reference is directed to “Heterogeneous Reactions: Analysis, Examples, and Reactor Design, Vol. 2: Fluid-Fluid-Solid Reactions” by L K Doraiswamy and M M Sharma, John Wiley & Sons, New York (1994) and to “Chemical Reaction Engineering” by O Levenspiel, Wiley Eastern Limited, New Delhi (1972). Cumene selectivity was calculated from the weight ratio of DIPB/cumene which was expressed as percentage.
[0098] The results of the evaluation of the catalysts of the invention A and D were compared with two different formulations of MCM-22 catalysts B, C as set out in the below table. The activity of the catalyst was normalized on the activity of Catalyst B.
[0000]
TABLE 1
Normalized
Normalized
Selectivity
% DIPB/
Catalyst
Description
Activity %
% DIPB/IPB*
IPB**
A
Example 1, in-
166
20.3
120
situ MCM-22
extrudate,
0.16 cm cylinder
B
Conventional
100
16.9
100
MCM-22 bound
with alumina in
0.16 cm cylinder
extrudate
C
Conventional
171
20.8
123
MCM-22 bound
with alumina in
0.127 cm
quadrulobe
extrudate
C
(repeated run)
180
19.1
113
D
Example 3, in-
274
21.1
125
situ Beta/MCM-
22 extrudate,
0.127 cm
quadrulobe
extrudate
DIPB = diisopropylbenzene
IPB = isopropylbenzene
*Normalized to 1 gram cat load
**Normalized to Catalyst B performance
[0099] It is known that for propylene alkylation of benzene, the reaction is diffusion limited, and extrudate with a high surface to volume ratio should normally have a higher activity. From the results, catalyst A, despite having a lower surface to volume ratio in comparison to catalyst C, has similar activity and selectivity (% DIPB/IPB). Also, in comparison to the conventionally produced MCM-22 catalyst B of the same extruded shape, catalyst A has much higher activity, and slightly higher % DIPB/IPB. The catalyst comprising a molecular sieve as produced by the method of the present invention shows dramatically higher activity than an alumina bound conventionally produced MCM-22 extrudate.
[0100] The unique properties of the resulting extrudates found from this invention include one or more of high surface area, high porosity, high crush strength, high activity, and an intergrown-crystal morphology. The H-form extrudate was tested in an aromatics alkylation unit and showed very encouraging performances for both activity and selectivity. The performance of the catalyst crystals can also be further enhanced by post treatments such as with water, mild acid solution washing, or metal oxide surface modification which are well known performance enhancing methods. | The invention relates to a crystalline molecular sieve composition which is obtainable by crystallizing a pre-formed extrudate mixture in a reactor and, during crystallization, removing excess alkali metal hydroxide from the pre-formed extrudate. The pre-formed extrudate mixture comprises at least one source of ions of tetravalent element Y, at least one source of alkali metal hydroxide, water, optionally at least one seed crystal, and optionally at least one source of ions of trivalent element X. The reaction mixture has the following mole composition: Y:X 2 =10 to infinity; OH − :Y=0.001 to 2; and M + :Y=0.001 to 2; wherein M is an alkali metal. The amount of water in the mixture is at least sufficient to permit extrusion of said reaction mixture. | 8 |
FIELD OF THE INVENTION
This invention relates to a shift control apparatus for an automatic transmission for a vehicle, in which hydraulic pressures supplied to a plurality of frictional engaging elements are individually controlled to achieve a plurality of speed ratios, especially, allowing the driver to achieve positive starting of the vehicle even when the shift lever is slowly operated from the N position to the D position.
BACKGROUND OF THE INVENTION
An automatic transmission for a vehicle selectively supplies hydraulic fluid to frictional engaging elements such as clutches and brakes to connect a desired rotary element in its gear system to an input shaft of the transmission or fix the element to the transmission casing, thereby automatically changing the speed ratio according to operation conditions of the vehicle.
Such an automatic transmission for a vehicle is required to be small in speed-shift shocks to protect various parts and components and maintain comfortable drive feeling. For this purpose, an automatic transmission for a vehicle has been proposed which uses a proper electronic control over the hydraulic pressure and its supply timing to frictional engaging elements, aiming to achieve reduced speed-shift shocks.
As shown in FIG. 5 which shows an example of the structure of such an automatic transmission for a vehicle, a crank shaft 12 of an engine 11 is integrally connected with an impeller 14 of a torque converter 13. The torque converter 13 has the impeller 14, a turbine 15, a stator 16, and a one-way clutch 17. The stator 16 is connected to a transmission casing 18 through the one-way clutch 17. By the function of the one-way clutch, the stator 16 is allowed to rotate in the same direction as the crank shaft 12 but is not allowed to rotate in the reverse direction. The torque transmitted to the turbine 15 is transmitted to the input shaft 19 (hereinafter referred to as the "transmission input shaft") of a gear transmission apparatus to achieve four forward speeds and a single reverse speed disposed at the rear of the torque converter 13.
The gear transmission apparatus comprises three clutches 20, 21, and 22, two brakes 23 and 24, one one-way clutch 25, and one ravigneaux type planetary gear mechanism 26. The ravigneaux type planetary gear mechanism 26 comprises a ring gear 27, a long pinion gear 28, a short pinion gear 29, a front sun gear 30, a rear sun gear 31, and a carrier 32 which rotatably supports the pinion gears 28 and 29 and is rotatably engaged with the transmission input shaft 19.
The ring gear 27 is connected to a transmission output shaft 33. The front sun gear 30 is connected to the transmission input shaft 19 through a kickdown drum 34 and a front clutch 20. Furthermore, the rear sun gear 31 is connected to the transmission input shaft 19 through a rear clutch 21. The carrier 32 is connected to the transmission casing 18 through a low reverse brake 24 and the one-way clutch 25 and to the transmission input shaft 19 through a 4th-speed clutch 22 disposed at the rear end of the gear transmission apparatus. The kickdown drum 34 is integrally connectable to the transmission casing 18 by a kickdown brake 23. Torque passed through the ravigneaux type planetary gear mechanism 26 is transmitted from a drive gear 35 mounted to the transmission output shaft 33 to the drive shaft side of driving wheels (not shown).
The clutches 20 to 22 and the brakes 23 and 24 as frictional engaging elements individually comprise hydraulic mechanisms provided with engaging piston devices or servo mechanisms. These hydraulic mechanisms are operated through a hydraulic control unit (not shown) by hydraulic fluid generated by an oil pump 36 connected to the impeller 14 of the torque converter 13.
Detailed structure and functions of the mechanisms are already known, for example, in Japanese Patent Publication Laid-open 58-54270/1983, 58-46248/1983, or 61-31749/1986. Thus, selective engagement of various frictional engaging elements is achieved according to the position of a shift lever provided beside the driver's seat of the vehicle (not shown) selected by the driver and operation conditions of the vehicle, and various speed ratios are automatically achieved through the hydraulic control unit according to instructions from an electronic control unit to control the operation conditions of the engine 11.
The select pattern of the shift lever includes P (parking), R (reverse), N (neutral), D (automatic three forward speeds or automatic four forward speeds), 2 (automatic two forward speeds), and L (fixed to the 1st speed) positions. With the shift lever set to the D position, when an auxiliary switch (over-drive switch, not shown) is operated, the automatic three forward speeds or the automatic four forward speeds can be selected. The functions of the individual frictional engaging elements when the shift lever is set to the individual positions are shown in FIG. 6. In the figure, symbol "◯" indicates that an engagement condition is achieved by hydraulic operation, and symbol " " indicates that the engaging is achieved only when the L position is selected.
For example, when the shift lever is shifted from the N position to the D position during a standstill condition of the vehicle, from a condition where all of the frictional engaging elements are not engaged, only the rear clutch 21 is newly engaged to achieve the speed ratio of the 1st speed. However, during a standstill condition of the vehicle and when the accelerator pedal is not pressed down, the speed ratio of the 2nd speed is achieved in which further the kickdown brake 23 is lightly engaged, thereby preventing generation of an excessive creeping.
As shown in FIG. 7 which schematically shows the structure of the main portion of the hydraulic circuit in the hydraulic pressure control unit, the rear clutch 21 is connected with a rear clutch exhaust valve 37 through an oil passage 38, and the rear clutch exhaust valve 37 is connected with a N-D control valve 39 through an oil passage 40. The N-D control valve 39 which is supplied with hydraulic oil, of which the maximum pressure is regulated by a relief valve (not shown), from the oil pump 36 through an oil passage 41, and a 1-2 shift valve 44 which connects an oil passage 43 to a kickdown servo 42 which controls the operation of the kickdown brake 23 connect through an oil passage 45, and the 1-2 shift valve 44 is connected to a shift control valve 46 through an oil passage 47. A manual valve 48 which is mechanically linked with operation of the shift lever is connected to an oil passage 49 branched from the oil passage 41 to supply a line pressure to the manual valve 49, and the shift control valve 46 and the manual valve 48 connect through an oil passage 50. An oil passage 51 branched halfway from the oil passage 50 is connected with a hydraulic pressure control valve 52, and the hydraulic pressure control valve 52 is connected also to the N-D control valve 39 through an oil passage 53. Furthermore, the manual valve 48 and the N-D control valve 39 connect through an oil passage 54 branched halfway from the oil passage 51.
The hydraulic pressure control valve 52 supplies the line pressure supplied to the oil passages 50 and 51, adjusted by a reducer valve (now shown) to a lower pressure than the line pressure and controlled to a desired pressure according to the control hydraulic fluid supplied from the oil pump 36, to the oil passage 53 through an oil passage 55. Control hydraulic pressure in the oil passage 55 is adequately discharge-controlled by an oil pressure control electromagnetic valve of a type which closes when unenergized according to an instruction from an electronic control unit (hereinafter described as ECU) 56 so that a desired pressure is obtained.
The shift control valve 46 is controlled by a pair of shift control electromagnetic valves of a type which closes when unenergized of which the combination of actuation conditions is controlled by ECU 56, so that a central spool 60 is select controlled to positions corresponding to the 1st to 4th speed ratios.
In this case, when the shift lever is the N position as shown in FIG. 7, the line pressure from the oil passages 41 and 49 is not supplied to the oil passage 50 and 51 side, the rear clutch 21 and the kickdown brake 23 are not engaged, the transmission input shaft 19 runs idle, and the driving force from the engine 11 is not transmitted to the transmission output shaft 33.
From this condition, when the driver operates the shift lever to select the D position, and when the vehicle is in a standstill condition and the accelerator pedal is not pressured down, as shown in FIG. 8 which shows the relationship between the position of the shift lever at that time, an output signal from an inhibitor switch, a duty ratio of the hydraulic pressure control electromagnetic valve 57, the line pressure and a creep pressure supplied to an engaging side oil chamber 65 of the kickdown servo 42, only the shift control electromagnetic valve 59 of the pair of shift control electromagnetic valves 58 and 59 to control the operation of the shift control valve 46 is energized, and the line pressure from the oil passages 41 and 49 is supplied to the oil passage 50 and 47 through the central spool 60 of the shift control valve 46.
This moves the spool 61 of the 1-2 shift valve 44 to the right in FIG. 7, causing the oil passages 45 and 43 to communicate with each other. Furthermore, at the same time the shift lever is turned over from the N position to the D position, the inhibitor switch is turned on to supply the line pressure from the oil passage 51 to the oil passages 54 and 45, rapidly raising the hydraulic pressure in the oil passage 43 connecting to the kickdown servo 42 in area (1), and to the rear clutch 21 through the oil passages 53, 40, 38 to remove play of the rear clutch 21, reverting it back to the condition immediately before the engagement. In this case, since the rear clutch 21 is pressed by the amount of play, the line pressure in the oil passage 40 is not raised and, in turn, the line pressure in an oil passage 62 is not raised, a spool 63 of the N-D control valve 39 is positioned at the left end, as shown in FIG. 7.
After that, in area (2), the hydraulic pressure control electromagnetic valve 57 is actuated by the duty control, a spool 64 of the hydraulic pressure control valve 52 is intermittently moved to the left side in FIG. 7, causing the oil passage 53 to communicate with an oil discharge port EX of the hydraulic pressure control valve 52. As a result, a hydraulic pressure (hereinafter called the creep pressure), adjusted to a lower pressure than the line pressure from the oil passage 51, is supplied from the oil passage 53 to the N-D control valve 39, and from the oil passage 40 via the rear clutch exhaust valve 37 and the oil passage 38 to the rear clutch 21. This causes the rear clutch 21 to mildly engage, thereby reducing shocks associated with the engagement.
In area (3), the duty ratio of the hydraulic pressure control electromagnetic valve 57 decreases to 0%, and the line pressure from the oil passage 51 is, as is, supplied to the rear clutch 21 via the oil passage 38, achieving a complete engagement of the rear clutch 21. At the same time, the line pressure from the oil passage 51 passes through the oil passage 62 and acts on the left end in FIG. 7 of the spool 63 of the N-D control valve 39. The spool 63 of the N-D control valve 39 moves to the right in FIG. 7 to act on the left end, the oil passage 54 and the oil passage 40 communicate with each other through the oil passage 62, and the oil passage 53 and the oil passage 45 communicate with each other.
After that, in area (4), the duty ratio of the hydraulic pressure control electromagnetic valve 57 temporarily increases to 100%, and the line pressure, which acted into an engaging side oil chamber 65 of the kickdown servo 42, is discharged from an oil discharge port EX of the hydraulic pressure control valve 52 through the oil passage 43, the 1-2 shift valve 44, the oil passage 45, the N-D control valve 39, and the oil passage 53.
Then, in area (5), the hydraulic pressure control electromagnetic valve 57 becomes conductive at a predetermined duty ratio, the creep pressure is supplied from the oil passage 53 to the N-D control valve 39, and the creep pressure is supplied from the oil passage 45 through the 1-2 shift valve 44 and the oil passage 43 to the engaging side oil chamber 65 of the kickdown servo 42. As a result, the kickdown brake 23 moderately engages to achieve the 2nd speed ratio, thereby suppressing generation of an excessive creeping.
In this condition, when the accelerator pedal is pressed down by the driver, both of the pair of shift control electromagnetic valves 58 and 59 become conductive to achieve the 1st speed ratio, the central spool 60 of the shift control valve 46 moves to the right end in FIG. 7 to close the oil passages 50 and 47, the spool 61 of the 1-2 shift valve 44 is pushed back to the left end in FIG. 7, the oil passage 43 becomes communicating with the oil discharge port EX of the 1-2 shift valve 44. This causes hydraulic fluid in the engaging side oil chamber 65 of the kickdown servo 42 to be rapidly discharged through the oil passage 43 from the oil discharge port EX of the 1-2 shift valve 44, and the kickdown brake 23 is released, immediately achieving the 1st speed ratio which engages with only the rear clutch 21.
In a prior art automatic transmission shown in FIGS. 5 to 7, in which a plurality of speed ratios are achieved by electronically controlling individual hydraulic pressures supplied to a plurality of frictional engaging elements to selectively engage these frictional engaging elements, when the shift lever is moved from the N position to the D position under a standstill condition of the vehicle, the position of the shift lever and the output signal of an inhibitor switch (not shown) are synchronized with the moving timing of a spool 66 of the manual valve 48, thereby achieving a smooth shift operation.
However, when the driver moves the shift lever from the N position to the D position very slowly, the output signal of the inhibitor switch changes over before the manual valve 48 moves from the N position to the D position to achieve complete communication between the oil passages 49 and 51, since the hydraulic pressure control unit duty controls the hydraulic control magnetic valve 57 according to the signal from the inhibitor switch, the creep pressure is supplied to the rear clutch 21 side before the spool 63 of the N-D control valve 39 does not completely move to the right in FIG. 7, and the rear clutch 21 tends to fail complete engagement.
Under such a condition, even if the driver presses down the accelerator pedal in order to start the vehicle, the rear clutch 21 tends to slip resulting in a difficulty in starting the vehicle, or deteriorating acceleration of the vehicle.
With a view to eliminate the above prior art problems, it is a primary object of the present invention to provide a shift control apparatus for a vehicle automatic transmission in which individual hydraulic pressures supplied to a plurality of frictional engaging elements are electronically controlled to achieve a plurality of speed ratios, which enables positive starting of the vehicle even when the driver slowly moves the shift lever from the N position to the D position to start the vehicle.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided, as a first embodiment, a shift control apparatus for an automatic transmission of a vehicle wherein a plurality of speed ratios are achieved by electronically controlling individual hydraulic pressures supplied to a plurality of frictional engaging elements to selectively engage these frictional engaging elements, comprising speed ratio select means for changing over the speed ratio of the vehicle automatic transmission from a neutral position to a running position, operation condition determination means for determining the operation condition of the vehicle, an electromagnetic valve for controlling a hydraulic pressure supplied to a first frictional engaging element to achieve a first speed, and electromagnetic valve control means for controlling operation of the electromagnetic valve so that when the speed ratio select means is determined by the operation condition determination means to be slowly manipulated, a supply time of a maximum hydraulic pressure to the first frictional engaging element is extended by a first predetermined time.
There is also provided according to the present invention, as a second embodiment, a shift control apparatus for an automatic transmission of a vehicle wherein a plurality of speed ratios are achieved by electronically controlling individual hydraulic pressures supplied to a plurality of frictional engaging elements to selectively engage these frictional engaging elements, comprising operation condition determination means for determining the operation condition of the vehicle, an electromagnetic valve for controlling individual hydraulic pressures supplied to a first frictional engaging element to achieve a first speed ratio and a second frictional engaging element to achieve a second speed ratio in cooperation with the first frictional engaging element, and electromagnetic valve control means for controlling the electromagnetic valve to achieve the second speed ratio when the vehicle is in a standstill condition and the engine is under a low load at the time the speed ratio of the vehicle automatic transmission is changed over from a neutral position to a running position, or when an increase in load on the engine is detected, hydraulic pressure is removed from the second frictional engaging element for a predetermined time and then a maximum hydraulic pressure is supplied to the first frictional engaging element to achieve the first speed ratio.
Thus, in the first embodiment of the present invention, when operation of the speed ratio select means is slow, the electromagnetic valve control means controls the operation of the electromagnetic valve so that the time for supplying a maximum hydraulic pressure to the first frictional engaging element is extended by a first predetermined time.
This enables positive engagement of the first frictional engaging element to achieve the first speed ratio even when hydraulic pressure to the first frictional engaging element to achieve the first speed ratio is low to some degree.
In the second embodiment of the present invention, when the vehicle is in a standstill condition and the engine load is low at the time the speed ratio of the vehicle automatic transmission is changed over from a neutral position to a running position, the electromagnetic valve control means controls the electromagnetic valve to achieve the second speed ratio, or when an increase in load on the engine is detected, the electromagnetic valve control means controls the electromagnetic valve to remove hydraulic pressure from the second frictional engaging element for a predetermined time and then supply a maximum hydraulic pressure to the first frictional engaging element whereby achieving the first speed ratio.
This positively releases the second speed ratio and achieves the first speed ratio when the vehicle starts from a creep control condition at the second speed ratio, thereby enabling smooth starting of the vehicle with minimized shift shocks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing an example of duty ratio control pattern of a hydraulic pressure control electromagnetic valve in an embodiment in which the shift control apparatus for a vehicle automatic transmission according to the present invention is applied to a vehicle equipped with an automatic transmission of four forward speeds.
FIG. 2 is a graph showing an example of duty ratio control pattern of a hydraulic pressure control electromagnetic valve at starting of the vehicle.
FIG. 3 and FIG. 4 are flow charts showing control flow of this embodiment.
FIG. 5 is a skeletal view showing structure of an automatic transmission of four forward speeds to which the present invention is applied.
FIG. 6 is an operation element chart showing the relationship between engagement condition of individual frictional engaging elements and speed ratios.
FIG. 7 is a hydraulic circuit diagram showing a main portion of the hydraulic pressure control unit.
FIG. 8 is a graph showing the relationship between the position of a shift lever, an inhibitor switch signal, the duty ratio of the hydraulic pressure control electromagnetic valve, a line pressure, and a creep pressure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The shift control apparatus for vehicle automatic transmission according tothe present invention can be applied, for example, to a vehicle equipped with an automatic transmission of four forward speeds as shown in FIG. 5 to FIG. 7, in which when the shift lever is operated slowly from an N position to a D position, as shown in FIG. 1 showing an example of controlpattern of its hydraulic pressure control electromagnetic valve 57, the duty ratio of the hydraulic pressure control electromagnetic valve 57 is set to 0% to extend area (3), which is a wait time until a rear clutch 21 achieves a complete engagement by a line pressure, to area (3)'. This causes the rear clutch 21 in the course of engagement to go to creep control of (4) and (5), thereby preventing complete engagement failure of the rear clutch 21.
When the vehicle is started from the above creep control condition, both ofa pair of shift control electromagnetic valves 58 and 59 are energized in order to achieve a first speed ratio, a central spool 60 of a shift control valve 46 is moved to the left end in FIG. 7 to close oil passages 50 and 47, a spool 61 of a 1-2 shift valve 44 is pushed back to the left end in FIG. 7, and an oil passage 43 beocmes communicating with an oil discharge port EX of the 1-2 shift valve 44. As a result, hydraulic fluid in an engaging side oil chamber 65 of a kickdown servo 42 is rapidly discharged to release a kickdown brake 23, thereby immediately achieving the 1st speed ratio in which only the rear clutch 21 engages.
At this moment, a spool 63 of an N-D control valve 39 is required to have moved to the D position side (the right side in FIG. 7) corresponding to the position change of a shift lever from the N position to D position. Inorder to positively achieve this, the duty ratio of the hydraulic pressure control valve 57 is maintained at 0% for a predetermined time to exert thehigh line pressure on the oil passage 62 through the oil passage 53, thereby moving the spool 63 of the N-D control valve 39 to the right.
However, when the change-over operation of the shift lever from the N position to the D position is even further slowly performed so that the shift lever is stopped between the N position and the D position, since the amount of hydraulic fluid discharged from a manual valve 48 is limited, there may occur a defect that the rear clutch 21 cannot be completely engaged, even with the extension control over the waiting time until complete engagement of the rear clutch 21, and such defect makes theN-D control valve 39 unable to move to the right side, then allowing the N-D control valve to remain at the left-end position.
Then, as shown in FIG. 2(7)', the time to set the duty ratio of the hydraulic pressure control electromagnetic valve 57 to 0% is extended to secure through hydraulic pressure to be supplied for the hydraulic fluid paths 40 and 62 for positively supplying the line pressure to the rear clutch 21, thereby enabling the rear clutch 21 to achieve complete engagement and the spool 63 of the N-D control valve 39 to achieve positive movement to the right, in order to prevent poor starting and deterioration in acceleration. After that, in area (8), the duty ratio of the hydraulic pressure control electromagnetic valve 57 is set to 100% to complete the starting control.
In this case, when a shift instruction to the 1st speed is outputted to release from the creep control, the duty ratio of the hydraulic pressure control electromagnetic valve 57 is temporarily set to 100% in area (6) shown in FIG. 2. This operation will be briefly described below.
Normally, in the shift control from the creep control to the first speed ratio, a simple shift from (5) in FIG. 2 to (7) or (7)' has no problem. However, for a case when the viscosity of automatic transmission fluid is high at low temperatures or the like, moving of the 1-2 shift valve 44 to the first speed ratio side (left side in FIG. 7) in association with operation of the hydraulic pressure control electromagnetic valve 57 tendsto delay, and if the above control is performed in such a case, the line pressure will be supplied to the kickdown servo 42. As a result, the 2nd speed ratio will temporarily be achieved and then the speed ratio will return to the 1st speed ratio, resulting in shift shocks.
Therefore, as shown in FIG. 2(6), the duty ratio of the hydraulic pressure control electromagnetic valve 57 is set to 100% for a moment to discharge hydraulic pressure in the kickdown servo 42 from the oil discharge port EXof the hydraulic pressure control valve 52 through the N-D control valve 39, thereby preventing the problem of achieving the 2nd speed ratio, even if the 1-2 shift valve 44 is at the 2nd speed ratio side.
To determine whether or not the shift lever is slowly operated from the N position to the D position, determination is made in this embodiment from a vehicle speed V and a rotation speed of a turbine 15 of a torque converter 13. Specifically, as shown in FIG. 5 and FIG. 7, there are provided an oil temperature sensor 67 for detecting the temperature of automatic transmission fluid, an output shaft rotation sensor 68 for detecting a rotation speed N o of a transmission output shaft 33, an input shaft rotation sensor 69 for detecting a rotation speed N i of atransmission input shaft 19, an inhibitor switch 70 for detecting the position of the shift lever, and a throttle opening sensor 71 for detecting an opening θ of a throttle valve (not shown) (hereinafter referred to as "throttle opening") of the engine 11, and detection signalsfrom these sensors are outputted to ECU 56.
When an oil temperature T is above 0° C. according to the detection signal from the oil temperature sensor 67, the vehicle speed V is 0 km/hour according to the detection signal from the output shaft rotation sensor 68, and the rotation speed N i of the transmission input shaft 19 after one second from reception of a D signal from the inhibitor switch70 according to the detection signals from the inhibitor switch 70 and the input shaft rotation sensor 69, ECU 56 determines that the shift lever is slowly operated from the N position to the D position. Furthermore, when the vehicle speed V is more than 5 km/hour according to the detection signal from the output shaft rotation sensor 68 and the throttle opening θ is greater than 10%, it is determined that the driver desires to start the vehicle.
In this case, when the oil temperature T is below 0° C., a differentcontrol corresponding to this condition will be performed in order to eliminate problems associated with a high viscosity of automatic transmission fluid. Control according to the present invention is performed only when the oil temperature T is higher than 0° C. so that the control according to the present invention does not interfere in such a different control. Furthermore, when the shift lever is operated from the N position to the D position and the vehicle is in a standstill condition, the rotation speed N i of the transmission input shaft 19 should be 0 rpm, and if the transmission input shaft 19 rotates at a certain speed, it can be regarded that the rear clutch 21 is not completely engaged. Therefore, control according to the present invention is performed when the rotation speed N i of the transmission input shaft 19 is higher than 205 rpm after one second from reception of a D signal from the inhibitor switch 70.
When the rotation speed N o of the transmission output shaft 33 is morethan 300 rpm and the rotation speed N i of the transmission input shaft19 becomes more than 1,000 rpm while the control of the present invention is performed to maintain the shift lever at the D position, since the hydraulic pressure supplied to the rear clutch 21 has sufficiently risen, and the rear clutch 21 can be regarded to be in a complete engagement, thecontrol according to the present invention is released when the vehicle is restarted from this condition.
As shown in FIG. 3 and FIG. 4 showing the control flow of this embodiment, when ECU 56 receives a D signal from the inhibitor switch 70 in step S1, determination is made in step S2 as to whether or not the oil temperature T of automatic transmission fluid is above 0° C. according to a detection signal form the oil temperature sensor 67. When it is determinedin step S2 that the oil temperature T of automatic transmission fluid is above 0° C., determination is made in step S3 as to whether or not the vehicle speed V is 0 km/hour. When it is determined in step S3 that the vehicle speed V is 0 km/hour, that is, the vehicle is in a standstill condition, determination is made in step S4 as to whether or not the rotation speed N i of the transmission input shaft 19 is more than 205rpm after one second from receiving the D signal.
When it is determined in step S4 that the rotation speed N i of the transmission input shaft 19 is more than 205 rpm after one second from receiving the D signal, that is, the rear clutch 21 is insufficiently engaged, in step S5 the waiting time (3) in FIG. 1 to set the duty ratio of the hydraulic pressure control electromagnetic valve 57 to 0% is extended to (3)'. This extends the waiting time until complete engagement of the rear clutch 21 by the line pressure, and the operation transfers tothe creep control in (4) and (5) in FIG. 1 with the rear clutch 21 in the course of engaging, thereby minimizing the possibility of creep pressure to be supplied to the rear clutch 21.
Then, determination is made in step S6 as to whether or not the vehicle speed V is less than 5 km/hour and the throttle opening θ is less than 10%. When it is determined in step S6 that the vehicle speed V is less than 5 km/hour and the throttle opening θ is less than 10%, that is, the driver does not desire starting the vehicle, creep control of(4) and (5) in FIG. 1 is performed in step S7 to duty control the hydraulicpressure control electromagnetic valve 57 at the 2nd speed ratio.
Furthermore, determination is made in step S8 as to whether or not the vehicle speed V is more than 5 km/hour and the throttle opening θ ismore than 10%. When it is determined in step S8 that the vehicle speed V ismore than 5 km/hour and the throttle opening θ is more than 10%, thatis, the driver desires to start the vehicle, in step S9 the waiting time (7) in FIG. 2 to set the duty ratio of the hydraulic pressure control electromagnetic valve 57 to 0% from creep control of (5) and (6) is extended to (7)'. This even further increases the waiting time for engagement of the rear clutch 21, thereby achieving positive engagement ofthe rear clutch 21.
On the other hand, when it is determined in step S2 that the oil temperature T of automatic transmission fluid is below 0° C., that is, shift control at low temperatures is required, or when it is determined in step S3 that the vehicle speed V exceeds 0 km/hour, that is,the vehicle is not in a standstill condition, or when it is determined in step S4 that the rotation speed N i of the transmission input shaft 19after one second from receiving the D signal from the inhibitor switch 70 is less than 205 km/hour, that is, engagement of the rear clutch 21 is almost completely achieved, in step S10 the hydraulic pressure control electromagnetic valve 57 is duty controlled as in the past, that is, with a normal timing as shown by the two-dot-bar line in FIG. 1 and FIG. 2.
Furthermore, when it is determined in step S6 that the vehicle speed V is not less than 5 km/hour and the throttle opening θ is not less than 10%, that is, the driver desires to start the vehicle, normal starting control is performed in step S11.
Alternatively, when the shift lever is slowly shift from N position to the D position, it is of course possible to use other methods than described in this embodiment. Moreover, it is of course possible to use vehicle automatic transmissions and hydraulic pressure control devices of different structures other than described in this embodiment, for example,those disclosed in U.S. Pat. No. 3,754,482 and U.S. Pat. No. 4,770,789.
The shift control apparatus for a vehicle automatic transmission according to the present invention can be used in vehicles equipped with vehicle automatic transmissions in which individual hydraulic pressures supplied to a plurality of frictional engaging elements are electronically controlled to achieve a plurality of speed ratios by selectively engaging these frictional engaging elements. | A shift control apparatus for an automatic transmission of a vehicle wherein a plurality of speed ratios are achieved by electronically controlling individual hydraulic pressures supplied to a plurality of frictional engaging elements to selectively engage these frictional engaging elements, which includes speed ratio select members for changing over the speed ratio of the automatic transmission from a neutral position to a running position, operation condition determination members for determining operation condition of the vehicle, an electromagnetic valve for controlling hydraulic pressure supplied to a first frictional engaging element to achieve a first speed; and electromagnetic valve control members for controlling operation of the electromagnetic valve so that when the speed ratio select members is determined by the operation condition determination means to be slowly manipulated, a supply time of a maximum hydraulic pressure to the first frictional engaging element is extended by a predetermined time, whereby achieving positive starting of the vehicle even when the speed ratio select means is slowly manipulated from the neutral position to a running position. | 5 |
FIELD OF THE INVENTION
The present invention relates to a shock-absorbing transport and storage wrapping made from two webs of flexible material, preferably of plastics or plastic laminates, having gas or air filled spaces between said webs.
BACKGROUND AND OBJECTS OF THE INVENTION
Refrigerators and freezers, washing machines and similar prismatic articles are frequently damaged during transport from the manufacturer to the user. Even if the goods is well wrapped, shocks or collisions against other objects may tear or deform the wrapping.
One object of the present invention is to provide a shock-absorbing wrapper which may be applied along corner-portions of the article. This gives a protection not only to the corner as such but the side surface between two corner wrapper strings will be maintained at a certain distance from other objects.
One additional object of the invention is to provide a technique which offers an optimum of transport and storage protection for products wrapped in a wrapping having preformed cavities of individually variable size and shape.
Another object of the invention is to provide an efficient wrapper manufacturing method.
STATE OF THE ART
From the packaging technique within the electronics industry there are known webs having formed therein small (in the size of 10 to 20 mm) spheres filled by air and spaced in a close sphere to sphere-pattern. Such wrappers do provide shock-absorption in combination with an outer protective package, generally a cardboard box. Sheets of said wrappers are simply placed along the planar innersides of the box.
Another known technique makes use of elongated, blown up, air filled, proximate cylindric spaces between the pair of flexible webs. Such technique does also provide a restricted pattern configuration for the protective elements of the wrapping. The configuration may be described as a "nodistance" cylinder to cylinder configuration. The cylinders are so close to each other that the web loses its folding characteristics.
SUMMARY OF THE INVENTION
A shock absorbing wrapper according to the present invention is characterized by two flexible webs, at least one of which is thermoformable, permanently formed and joined such that at least two rows of gas-filled cushions of arbitrary size and shape are formed, the width of the web being such that at least two rows of cushions are separated a distance allowing the rows to be folded relative each other.
A method for manufacturing of a shock-absorbing wrapper of the type comprising two weldable flexible webs is characterized in that series of gas-filled cushions of arbitrary shape and dimension are formed in one of said webs by a thermoforming process in a thermoforming machinery, and that the two webs are moved past stations for length-wise and cross-wise welding, and in that the width of the webs are such and the welding station placed such that at least two rows of cushions are formed, separated by a distance sufficient for allowing the rows of pillows to be folded against each other.
In order to safeguard the protective funtion of the cushions, a gas, preferably air, is blown in between the webs just before the welds of each individual, thermoformed recess are finished.
One article, for instance a freezer, is transferred from a wrapping station on a wooden pallet and is protected by a cardboard wrapper and/or wooden frames. A shock-absorbing wrapper according to the present invention is applied at least along the vertical corner-portions. Thereafter a shrink film is applied around the object, and after being heated the shrink film fixes the freezer, pallet and any wooden frames plus the shock-absorbing corner wrappers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows a freezer being wrapped by corner-protection means according to the present invention,
FIG. 2 shows a portion of a wrapper band according to the present invention,
FIG. 3 shows a section through the band, but with the longitudinal portions of the band folded 90° relative each other,
FIG. 4 very schematically shows the method of manufacturing the wrapping band,
FIG. 5 is a cross-section taken from FIG. 4,
FIG. 6 is a plan view showing the side of the band having specific cushions according to a second embodiment,
FIG. 7 is a section along line VII--VII in FIG. 6, and
FIG. 8 is a broken section along line VIII--VIII.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1 the reference numeral 10 denotes an arbitrary, prismatic article, for instance a freezer, which should be wrapped and transported, standing on a pallet 11. In the traditional manner the freezer may be wrapped by corrugated cardboard.
In order to protect the freezer efficiently during the transport, bands of pressurized, thermoformed cushions are attached along the vertical corner-portions of the freezer. Possibly, similar bands may be attached along the upper horizontal corner-portions.
As appears best from FIG. 2, each band 12 comprises two rows 13 of pillows 14 having four-sided planar shape. The rows of cushions are seperated by a solid strip 15 which is wide enough for allowing folding of the band such that the rows of cushions will be placed 90° relative each other, as shown in FIG. 3.
The bands 12 may be glued to the corrugated cardboard wrapper. In that case where this wrapper is enforced by wooden frames, the band may be stitched to such applications which is best carried out by a robot.
Finally, the entire unit is enclosed within shrinkable plastics which after heating tightens the seperate elements to a unit and forms a reinforced transport protection.
The manufacture of the band is carried out as schematically shown in FIG. 4, where basically a thermoforming machinery is shown operating from a pair of rollers carrying webs of thermoformable material.
Two webs 16, 17 of plastic foil, preferably a LD-polyethylene, are unrolled from rollers 18, 19 and transported generally in a horizontal direction past stations for thermoforming recesses forming bladders after being sealed by the other web. The recesses have a formstable shape also when the bladders are unpressurized. In one embodiment the bladders are given a four-sided planar shape and arranged such that they cover a substantial portion of the surface of the band, only surrounded by the necessary weld seams.
In order to give the cushions a sufficient depth and predetermined lateral dimensions for the intended shock-absorption function, the bladders are permanently thermoformed with a minimum of mechanical memory from at least one of the webs.
At 20 there is shown a station for forming recesses 21 by thermoforming, i.e. a certain portion of the material of the strip is heated and sucked and/or pressed into a mold.
The two bands 16, 17 are thereafter brought to pass a sealing station 22 for longitudinal welding of the webs 16, 17.
In a manner known per se the station 22 may comprise the traditional heat sealing equipment or heated wheels 23 for welding webs along the outer longitudinal edges, as well as between the recesses or bladders 21 so that there is obtained an elongated strip for folding of the webs.
Gas, preferably air, is blown in between the bands 16, 17 from a source for pressurized air 24 immediately before the welding station 22, such that the recesses covered by the other web are safely pressurized by gas before they are sealed to cushions 14 which takes place in the welding station 25 where heated jaws operate in the cross-wise direction between the bladders 21.
The band manufactured in the described manner may be rolled up or folded in a storage, from which it may be taken out as desired, but of course the machinery may operate also intermittently and produce bands as desired and feed such out from the machinery in desired predetermined lengths.
The two rows of gasfilled, pressurized cushions in the embodiment according to FIGS. 1-5 having a square/rectangular basic shape offer an excellent protection for corner-portions as well as surfaces therebetween. Possibly, both webs may be provided with bladders, and the attachement to the object to be transported may be carried out in different manners. The lower web 17 having no bladders may for instance be provided with a layer of glue covered by a removable protective film.
In FIG. 8 there is shown a tool to be used in a conventional thermoforming machine for forming "bladders" or recesses of basically two different types (or alternatively FIG. 8 may be said to represent a cut piece of a sealed two web wrapper having been thermoformed in said tool).
The section in FIG. 7 shows two different types for the bladders 26, 27 and a certain region 28 therebetween where the two webs are sealed.
The reference numerals 29, 30 represent folding denotations for facilating the folding of the piece of band, generally to any required angle between 0-90° around a horizontal axis.
FIG. 8 shows the hight 30 and length 31 of the cushions in the vertical direction in said fig.
The possibility of providing permanently deformed, possibly gas-filled and pressurized, cushions or bladders improves drastically the protecting ability of the wrapping. Even if one or several bladders are punctured, such bladders maintain a shock-absorbing capacity also after being depressurized because the punctured bladder acts as a shock-absorber from which gas has to be pumped out through the punctured areas. Basically, the thermoforming procedure does also allow a 100% tailored piece of cushion band for a specific shock-absorbing purpose, meaning that the wrapping will act at an optimum irrespective of the shape of the article on which it is fastened. | A customized shock-absorbing wrapper band comprising at least two rows of gas-filled cushions of arbitrary shape and size formed by joining two flexible webs, at least one of which is thermoformable, and pressurizing the thermoformed recesses when sealing such by the other web in a sealing station of a thermoforming, roller operated machine. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to a process for purifying long-chain dicarboxylic acids and the production thereof, especially relates to a process for purifying long-chain dicarboxylic acids without using any organic solvents and the production thereof
BACKGROUND OF THE INVENTION
[0002] Long-chain dicarboxylic acids are used as important raw material for synthesizing such products as Nylon, high-grade perfume, plasticizers, lubricants, as well as advanced thermosols. Nowadays various types of long-chain dicarboxylic acids are mainly produced as metabolic products is obtained from the fermentation with n-alkane by microorganisms such as Candida tropicalis. However the fermentation liquid is a complex multi-phase system which contains unreacted n-alkane, unutilized culture medium, cells of microorganisms and inclusions thereof, secretion substances of the microorganism and the like, especially in which a large amount of impurities, such as proteins and pigments, will have serious effect on the purity and appearance of the long-chain dicarboxylic acid the product.
[0003] Currently, the process for purifying the long-chain dicarboxylic acid is typically classified into two types: a process using organic solvents and a process using water. The process using organic solvents is significantly restricted by the problems such as high investment, residual alkane and solvent in the product, safety of production and so on. The process using water can overcome the defects that the solvent process has, however, the purity of its product using the current techniques cannot attain to a high level required by polymerization. For example, JP56026194 disclose an aqueous phase process for separating dicarboxylic acid, wherein the purification steps comprise alkalifying and stewing the fermentation liquid, centrifuging to remove microorganism, adding siliceous earth to adsorb unreacted reactants and by-products, then filtering, acidifying and depositing the filtrate. Finally, the product of dicarboxylic acid is obtained after filtration and drying. The problem existing in the processes mentioned above is the autolysis of cells during alkalifying and stewing, thereby the impurities such as proteins and coloring materials in cells are dissolved into the fermentation liquid, consequently the purity of total acid product is only 98.5% at highest, and the coloring materials in the product are difficult to be removed. The product is then light brown in appearance. Moreover, the main problem of the aqueous phase process is that monocarboxylic acid sodium salt is co-crystallized with dicarboxylic is acid monosodium salt or disodium salt. Thus it is hard to separate the dicarboxylic acid from similar monocarboxylic salt thereof.
[0004] CN1255483A disclosed a method for purifying long-chain dicarboxylic acid product by using crystallization of the monosalt of long-chain dicarboxylic acid. This method needs to precisely adjust the amount of base added in the fermentation liquid to make sure the dicarboxylic acid generating only the monosalt and avoiding to become the disodium salt. However it is hard to decide the exact amount of base when the mol. production ratio of the dicarboxylic acid is hard to predict. This defect leads to the yielding ratio of the product is rather low to about less than 90 wt % without recycling the dicarboxylic acid in the filter of the monosalt. And the yielding ratio of the product could reach to about 92 wt % with recycling the dicarboxylic acid in the filter of the monosalt, which however increases the processing costs. And the aqueous phase of the monosalt filter is not pure enough, and it is hard to remove the residual monosalt in the final production. CN1219530A disclosed a method for purifying long-chain dicarboxylic acid product by salting out with disodium salt. However the product ratio is still low and the filtration of the salting out also has to recycle to obtain the dicarboxylic acid.
[0005] CN1552687A disclosed a process for refining a long-chain dicarboxylic acid product by heating it to the melting points, and followed by addition of water to carry out cooling crystallization. After reaching the melting point, dicarboxylic acid which is floating on the surface of aqueous phase has been collected in the open environment. As melting points of most dicarboxylic acids with even number of carbons are above 110 degree Celsius, particular methods such as using highly concentrated saline to increase the water boiling temperature has been described in the patent. However such adjustment of the method confines is its application. Moreover, the separation of the dicarboxylic acid in the melting state has been proved very difficult: there are no obvious floating layers of the DC 10 , DC 12 and DC 13 . In addition, crystallization by adding water causes precipitation of both monocarboxylic and dicarboxylic acids. The crystals and the amorphous precipitates are also mixed together, which makes separation of the crystalised dicarboxylic acid difficult. Such method may solve the purification of the DC 5 , DC 7 and DC 9 , but it is very difficult to use such method to deal with the purification of the other dicarboxylic acid with even carbon number.
SUMMARY OF THE INVENTION
[0006] The purpose of the present invention is to provide a purifying and refining method for all the dicarboxylic acids by aqueous crystal without using any types of saline or organic solvents, and with no need to separate the dicarboxylic acid layer from the aqueous surface. More specifically, the method for purifying long-chain dicarboxylic acids includes the following steps:
[0007] 1) . Acidifying a liquid containing a long-chain dicarboxylic acid and/or a salt thereof, and collecting a crude product of the dicarboxylic acid which is in the crystal state or in the amorphous state;
[0008] 2) . Dissolving the crude product of the dicarboxylic acids using an alkaline solution with heating to obtain a solution, and filtering the solution to remove an insoluble material in the solution and decoloring with a decoloring agents to obtain a filtered solution;
[0009] 3) . Acidifying the filtered solution to adjust the pH value of the fermentation liquid to a range of 1˜2.5, then collecting a deposit of the dicarboxylic acid after centrifuging the filtered solution;
[0010] 4). Washing the deposit of the dicarboxylic acid to neutrality by adding water with a mass of 3 to 20 folds of that of the dicarboxylic acid is to re-suspend the dicarboxylic acid, heating the deposit of the dicarboxylic acid up to 60˜100° C., filtering, washing, and drying the deposit of the dicarboxylic acid to get a filtration cake of the dicarboxylic acid;
[0011] 5). Suspending the filtration cake of the dicarboxylic acid in water and heating a mixture of the filtration cake of the dicarboxylic acid and water up to a temperature above 100° C. under high pressure, and maintaining the temperature above a melting point of the dicarboxylic acid for 20˜30 minutes,
[0012] 6). Slowly dropping the temperature of the filtration cake of the dicarboxylic acid and water to a temperature in range of 25˜30° C. and procuring the dicarboxylic acid crystals by filtration.
[0013] Preferably, in the process 1) of the present invention, the pH value during the step of acidifying and depositing the filtrate is in a range of 1˜2.5, a temperature thereof is 60˜100° C.
[0014] Preferably, in the process 2) of the present invention, 5M NaOH is used as the alkaline solution to heat and melt the dicarboxylic acid, and the dealing condition is at 80° C. for one hour.
[0015] Preferably, in the method of filtering to remove the insoluble material of the process 2) of the present invention, the filter medium includes one kind or several kinds of gauze, ceramic film, metal film or glass fiber membrane is used.
[0016] Preferably, in the process 2) of the present invention, the decoloring agent used for decoloring is an activated carbon with 0.2% w or a siliceous earth with 0.5% w.
[0017] Preferably, in the process 4) of the present invention, the deposit of the dicarboxylic acid is wasted till a pH value of the dicarboxylic acid is in range of 6.5˜7.0.
[0018] Preferably, in the process 4) of the present invention, the mass of is said water used in washing the deposition of the dicarboxylic acid is 5 folds to that of the dicarboxylic acid.
[0019] Preferably, in the process 4) of the present invention, said water used in washing the deposition of the dicarboxylic acid is at 85° C. and with neutrality pH value, and the deposit of the dicarboxylic acid is washed 1-10 times repeatedly.
[0020] Preferably, in the process 5) of the present invention, said temperature is equal to the melting point of the dicarboxylic acid, and the duration of the heating is 10˜60 minutes.
[0021] Preferably, in the process 6) of the present invention, said temperature dropping process is to drop the temperature 10˜15° C. per hour.
[0022] Another purpose of the present invention is to provide dicarboxylic acids produced by using the method of anyone of the claims 1 - 11 , wherein no organic solvent is used in the purification process.
[0023] The above mentioned method could also be applied to organic solvent solution and solid crude product which contains dicarboxylic acid and/or a salt thereof In the cases of organic solvent solutions, removing any organic solvent then processing the above step 2); In the cases of solid crude product; starting from the above step 2); If starting from an aqueous solution containing a long-chain dicarboxylic acid and/or a salt thereof, starting from the above step 1).
[0024] Technical Solution:
[0025] The method of the present invention is much easier than the current application using organic solvent such as acetic acid. Therefore, the production ratio is much higher. Moreover, the water used in the crystallization could be used for washing the filtering cake and recycling. As without using acetic acid and with no acetic acid discharge, the method is much more advantaged for environmental protection. Finally, by using the method of falling down the temperature and filtering with water solution can acquire the dicarboxylic acid with higher purity up to 98.6%, and the crystallization of the dicarboxylic acid which is in the specific state and different from former purification methods is acquired. The present method of the invention is particularly suitable for the raw material for synthesizing products such as high-grade perfume and advanced thermosol and so on.
BRIEF DESCRIPTION OF THE FIGURES
[0026] FIG. 1A illustrates the crystals of the dodecanedicarboxylic acid produced by the method of the present invention;
[0027] FIG. 1B illustrates the crystals mixed with amorphous powder of the dodecanedicarboxylic acid produced by the method of the patent document CN102061316A (commercial product);
[0028] FIG. 2A illustrates the HPLC chromatogram of dicarboxylic acid crystallized using the method of present invention;
[0029] FIG. 2B illustrates the HPLC chromatogram of dicarboxylic acid crystallized using the method of the patent document CN102061316A (commercial product).
DETAILED DESCRIPTION OF THE INVENTION
[0030] The strain used in the embodiment of the present invention is Candida tropicalis UH-2-48 (deposit number CGMCC 0239, disclosed in CN1130685A). The crude production of the dicarboxylic acid from the fermentation of other strains, or the crude production of the dicarboxylic acid from synthetic chemistry method could use the same purification method described in the present invention.
[0031] Raw materials for producing dicarboxylic acids could be selected from alkanes with different chain length, various fatty acids or their esters. Dodecane, and sodium palmitate are used in the embodiment of the present invention. Various raw materials could be used in producing dicarboxylic acids with different chain length. The final temperature for heating up the mixture of a dicarboxylic acid can be referred to the following table 1.
[0000] TABLE 1 Suggested heating temperatures of the mixture of various dicarboxylic acids and water Number of carbon atoms Heating temperature ° C. 2 189-191 3 131-135 4 185-190 5 95-99 6 151-153 7 105-106 8 143-144 9 100-103 10 131-134 11 109-110 12 128-129 13 112-114 14 126-128 16 124-126 18 123-125
The present invention will be illustrated by the following examples.
EXAMPLE 1
[0032] 1. Culturing, seedling and fermentation of the strain for dodecanedicarboxylic acid production
[0033] The strain used in the embodiment of the present invention is Candida tropicalis UH-2-48(deposit number CGMCC 0239). A 50 ml starter culture is prepared from a conventional slant, and cultivated for 16 hours, followed by being transferred to a 1L secondary starter culture for another 16 hours. The starter culture contains corn syrup 0.2˜0.5% (w/v), yeast extract 0.3˜0.7% (w/v), urea 0.2˜0.5% (w/v), sucrose 2-5% (w/v), KH 2 PO 4 0.5˜1% (w/v), defoamer 0.03˜0.05% (v/v).
[0034] The aforementioned secondary starter culture is finally transferred to is a 10L fermenter tank to carry out the final fermentation. The basic media of the culture with a volume of 4L contains corn syrup 2-7% (w/v), NaCl 0.1%˜0.3% (w/v), yeast extract 0.15˜0.3% (w/v), urea 0.1˜0.25% (w/v), glucose 3˜7% (w/v), sucrose 0.5˜2% (w/v), KNO3 1˜2% (w/v), KH2PO4 0.5˜2% (w/v), cell regulators: 3˜7% (w/v), emulsifier 0.001˜0.05% (v/v), defoamer 0.03% (v/v). The fermentation is carried out for 144-156 h at 30° C. with a ventilation volume at 1:0.5. Dodecane is supplemented at the rate of 50 ml/h after the fermentation for 16 h till 150 g of dodecane (approximately 2L) is thoroughly supplemented. The pH value is controlled at 7.2 by 10M NaOH solution, and the dissolved oxygen is maintained at 20% through adjusting the rotational speed.
[0035] 2. Procurement of the crude dodecanedicarboxylic acid
[0036] 1) A 7L fermentation liquid, which is obtained in the above fermentation procedures with a final concentration of the total acid content at 187 g/l, is heated to 80° C. and maintained for 60 minutes.
[0037] 2) After pH value of NaOH (10M) is adjusted to 9.5, the yeast cells are removed by centrifuging.
[0038] 3) Active carbon powder at final amount of 0.5% (w/v) is added to the supernatant and the filtrate is incubated at 70° C., which is maintained for 60 minutes.
[0039] 4) Active carbon is removed by vacuum filtration with a 0.44 μm nylon membrane;
[0040] 5) The filtering solution is acidified to pH 2.5 by using 98% sulfuric acid, and incubated the filtering solution at 80° C. for 2 hours.
[0041] 6) The crude dodecanedicarboxylic acid is obtained by centrifuging the precipitate formed at the step 5). The precipitation is then washed by water and re-suspended, and then the precipitation is centrifuged, followed by vacuum drying to obtain the crude dodecanedicarboxylic acid.
[0042] 3. The pretreatment process before crystallization
[0043] 1) The crude dodecanedicarboxylic acid is re-dissolved by using 5M NaOH solution with a proportion of 1.74 g/ml, which is then heated to 80° C. and maintained for one hour. The solution containing re-dissolved dodecanedicarboxylic acid is then filtered to remove insoluble impurities with a piece of filter paper at 80° C. in a cabinet drier.
[0044] 2) Active carbon powder at a final amount of 0.2% (w/v) or siliceous earth at 0.5% (w/v) is then added to the filtrate, which is carried out at 60° C. and incubated at the temperature for 60 minutes.
[0045] 3) Active carbon or siliceous earth powder is removed by vacuum filtration with a 0.44 μm nylon membrane;
[0046] 4) The filtered-through solution is acidified to or lower than pH 2.5 using 98% sulfuric acid so that dodecanedicarboxylic acid is precipitated from the solution;
[0047] 5) The deposit of dodecanedicarboxylic acid is collected by centrifuging;
[0048] 6) The obtained dodecanedicarboxylic acid is then re-suspended and washed by using water with three-fold of the acid mass, followed by centrifuging. This washing step is repeated till the pH value of the washing supernatant is higher than 6.5. This washing step is usually carried out for three times. Water with mass of five-folds of that of the dicarboxylic acid is added and the suspension is heated to 80° C., is followed by filtration to get the filtered cake. The cake is then washed for three times using water at 85° C.
[0049] 4. The crystallization process of the dodecanedicarboxylic acid
[0050] 1) The filtering cake of the washed dodecanedicarboxylic acid is re-suspended in water with mass of five-folds of that of the filtering cake. The mixture is then heated to 128˜130° C. using a pressure vessel(GSHA-2 (2L), Henghua Chemical Plant, Weihai, P.R. China), and maintained the temperature for 20˜30 minutes.
[0051] 2) The temperature of the mixture is dropped continuously and slowly to the room temperature at a rate of 10° C. per hour. Dodecanedicarboxylic acid will be crystallized during the temerature dropping process;
[0052] 3) The crystallized dodecanedicarboxylic acid is obtained by centrifuging. Some float on the aqueous surface of the mixture, which contains monocarboxylic acid, is separated and removed using this method;
[0053] 4) The residual moisture is dried in a vacuum oven; and the purified dodecanedicarboxylic acid is procured.
[0054] The obtained dodecanedicarboxylic acid is 138.2 g in total, and the purity is 99.2%, the yield of product is 95.2%. The final product of dodecanedicarboxylic acid using the method of this example 1 showed crystal appearance ( FIG. 1A ), and that using the method of the example 1 of CN 102061316A showed amorphous appearance ( FIG. 1B ). The final product of dodecanedicarboxylic acid using the present invention is particularly suitable for downstream polymer synthesis such as polyamides, which requires highly pure precursors.
[0055] FIG. 2A illustrates the HPLC chromatogram at 210 nm and FIG. 2B at 254 nm. The condition of HPLC is using Agilent 1260, and the column is Zorbax Eclipse plus C18, the Diode Array Detector is G1315D. The mobile phase is 50% water: 50% acetonitrile at the beginning, and the end is 100% acetonitrile, and eluting in 30 minutes with the flow velocity of 1 ml/min. It can be concluded from the FIG. 2.A and FIG. 2.B that the purification and refinery process applied in the present patent can procure a product with the same quality as the current industrial product, even with less impurities.
EXAMPLE 2
[0056] 1. Culturing, seedling and fermentation of the strain for tridecanedicarboxylic acid production
[0057] The strain used in the embodiment of the present invention is Candida tropicalis UH-2-48(deposit number CGMCC 0239). A 50 ml starter culture is prepared from a conventional slant, and cultivated for 16 hours, followed by being transferred to a 1L further secondary starter culture for another 16 hours. The starter culture contains corn syrup 0.2˜0.5% (w/v), yeast extract 0.3˜0.7% (w/v), urea 0.2˜0.5% (w/v), sucrose 2˜5% (w/v), KH 2 PO 4 0.5˜1% (w/v), defoamer 0.03˜0.05% (v/v).
[0058] The aforementioned secondary starter culture is finally transferred to a 10L fermenter tank to carry out the final fermentation. The basic media of the culture with a volume of 4L contains corn syrup 2˜7% (w/v), NaCl 0.1%˜0.3%(w/v), yeast extract 0.15˜0.3% (w/v), urea 0.1˜0.25% (w/v), glucose 3˜7% (w/v), sucrose 0.5˜2% (w/v), KNO3 1˜2% (w/v), KH2PO4 0.5˜2% (w/v), cell regulators: 3˜7%(w/v), emulsifier 0.001˜0.05%(v/v), defoamer 0.03% (v/v). The fermentation is carried out for 144-156 hours at 30° C. with a ventilation volume at 1:0.5. Tridecane is supplemented at the rate of 50 ml/h after the fermentation for 16 hours till 150 g of tridecane (approximately 2L) is thoroughly supplemented. The pH value is controlled at 7.2 by 10M NaOH solution, and the dissolved oxygen is maintained at 20% through adjusting the rotational speed.
[0059] 2. Procurement of the crude tridecanedicarboxylic acid
[0060] 1) A 7L fermentation liquid, which is obtained in the above fermentation procedures with a final concentration of the total acid content at 177 g/l, is heated to 80° C. and maintained for 60 minutes.
[0061] 2) After pH value of NaOH(10M) is adjusted to 9.5, the yeast cells are removed by centrifuging.
[0062] 3) Active carbon powder at final amount of 0.5% (w/v) is added to the supernatant and the filtrate is incubated at 70° C., which is maintained for 60 minutes.
[0063] 4) Active carbon is removed by vacuum filtration with a 0.44 μm nylon membrane;
[0064] 5) The filtered-through solution is acidified to pH value 2.5 by using 98% sulfuric acid, followed by incubation at 80° C. for 2 hours.
[0065] 6) The precipitate formed at the step 5) The crude tridecanedicarboxylic acid is obtained by centrifuging the precipitate formed at the step 5). The precipitate is then re-suspended and washed by using water and then centrifuged again, followed by vacuum drying to obtain the crude tridecanedicarboxylic acid.
[0066] 3. The pretreatment process before crystallization
[0067] 1) The crude tridecanedicarboxylic acid is re-dissolved using 5M NaOH solution at a proportion of 1.65 g/ml, which is then heated to 80° C. and maintained for one hour. The solution containing re-dissolved tridecanedicarboxylic acid is then filtered to remove insoluble impurities with a piece of filter paper at 80° C. in a cabinet drier.
[0068] 2) Active a carbon powder with a final amount of 0.2% (w/v) or a siliceous earth with 0.5% (w/v) is then added to the filtrate, which is is carried out at 60° C. and incubated at the temperature for 60 minutes.
[0069] 3) Active carbon or siliceous earth powder is removed by vacuum filtration with a 0.44 μm nylon membrane;
[0070] 4) The filtered-through solution is acidified to or lower than pH value 2.5 by using 98% sulfuric acid so that tridecanedicarboxylic acid is precipitated from the solution;
[0071] 5) The deposition of tridecanedicarboxylic acid is collected by centrifuging;
[0072] 6) The obtained tridecanedicarboxylic acid is then re-suspended and washed using water with three-fold of the acid mass, followed by centrifuging. This washing step is repeated till the pH value of the washing supernatant is higher than 6.5. This washing step is usually carried out for three times. Water with mass of five-folds of that of the dicarboxylic acid is added and the suspension is heated to 80° C., followed by filtering to get the filtered cake. The filtering cake is then washed for three times using water at 85° C.
[0073] 4. The crystallization process of the tridecanedicarboxylic acid.
[0074] 1) The filtering cake of the washed tridecanedicarboxylic acid is re-suspended in water with mass of five-folds of that of the filtering cake. The mixture is then heated to 118˜120° C. using a pressure vessel(GSHA-2 (2L), Henghua Chemical Plant, Weihai, P.R. China), and maintained the temperature for 20-30 minutes.
[0075] 2) The temperature of the mixture is dropped continuously and slowly to the room temperature at a rate of 10° C. per hour. Tridecanedicarboxylic acid will be crystallized during the temperature dropping process;
[0076] 3) The crystallized tridecanedicarboxylic acid is obtained by centrifuging. Some float on the aqueous surface of the mixture, which contains monocarboxylic acid, is separated and removed using this method;
[0077] 4) The residual moisture is dried in a vacuum oven; and the purified tridecanedicarboxylic acid is procured.
[0078] The obtained tridecanedicarboxylic acid is 124.4 g in total, and the purity is 98.8%, the yield of product is 92.8%.
EXAMPLE 3
[0079] 1. Culturing, seedling and fermentation of the strain for hexadecanedicarboxylic acid production
[0080] The strain used in the embodiment of the present invention is Candida tropicalis UH-2-48(deposit number CGMCC 0239). A 50 ml starter culture is prepared from a conventional slant, and cultivated for 16 hours, followed by being transferred to a 1L further secondary starter culture for another 16 hours. The starter culture contains corn syrup 0.2˜0.5% (w/v), yeast extract 0.3˜0.7% (w/ v), urea 0.2˜0.5% (w/v), sucrose 2˜5% (w/v), KH 2 PO 4 0.5˜1% (w/v), defoamer 0.03˜0.05% (v/v).
[0081] The aforementioned secondary starter culture is finally transferred to a 10L fermenter tank to carry out the final fermentation. The basic media of the culture with a volume of 4L contains corn syrup 2˜7% (w/v), NaCl 0.1%˜0.3% (w/v), yeast extract 0.15˜0.3% (w/v), urea 0.1˜0.25% (w/v), glucose 3˜7% (w/v), sucrose 0.5˜2% (w/v), KNO3 1˜2% (w/v), KH2PO4 0.5˜2% (w/v), cell regulators: 3˜7% (w/v), emulsifier 0.001˜0.05% (v/v), defoamer 0.03% (v/v). The fermentation is carried out for 144-156 hours at 30° C. with a ventilation volume at 1:0.5. Sodium palmitate is supplemented at the rate of 50 ml/h after the fermentation for 16 hours till 0.5M of sodium palmitate (approximately 2L) is thoroughly supplemented. The pH value is controlled at 7.2 with by 10M NaOH is solution, and the dissolved oxygen is maintained at 20% through adjusting the rotational speed.
[0082] 2. Procurement of the crude tridecanedicarboxylic acid
[0083] 1) A 7L fermentation liquid, which is obtained in the above fermentation procedures with a final concentration of the total acid content at 248.5 g/l, is heated to 80° C. and maintained for 60 minutes.
[0084] 2) After pH value of NaOH (10M) is adjusted to 9.5, the yeast cells are removed by centrifuging.
[0085] 3) Active carbon powder at final amount of 0.5% (w/v) is added to the supernatant and the filtrate is incubated at 70° C., which is maintained for 60 minutes.
[0086] 4) Active carbon is removed by vacuum filtration with a 0.44 μm nylon membrane;
[0087] 5) The filtered-through solution is acidified to pH 2.5 value by using 98% sulfuric acid, followed by incubation at 80° C. for 2 hours.
[0088] 6)The crude tridecanedicarboxylic acid is obtained by centrifuging the precipitate formed at the step 5). The precipitate is then re-suspended and washed by using water and then centrifuged again, followed by vacuum drying to obtain the crude tridecanedicarboxylic acid.
[0089] 3. The pretreatment process before crystallization
[0090] 1) The crude tridecanedicarboxylic acid is re-dissolved by using 5M NaOH solution at a proportion of 1.40 g/ml, which is then heated to 80° C. and maintained for one hour. The solution containing re-dissolved tridecanedicarboxylic acid is then filtered to remove insoluble impurities with a piece of filter paper at 80° C. in a cabinet drier.
[0091] 2) Active carbon powder at a final amount of 0.2% (w/v) or siliceous earth at 0.5% (w/v) is then added to the filtrate, which is carried out at 60° C. and incubated at the temperature for 60 minutes.
[0092] 3) Active carbon or siliceous earth powder is removed by vacuum filtration with a 0.44 μm nylon membrane;
[0093] 4) The filtered-through solution is acidified to or lower than pH 2.5 value by using 98% sulfuric acid so that tridecanedicarboxylic acid is precipitated from the solution;
[0094] 5) The deposit of tridecanedicarboxylic acid is collected by centrifuging;
[0095] 6) The obtained tridecanedicarboxylic acid is then re-suspended and washed by using water with mass of three-folds of that of the acid, followed by centrifuging. This washing step is repeated till the pH value of the washing supernatant is higher than 6.5. This washing step is usually carried out for three times. Water with mass of five-folds of that of the acid mass is added and the suspension is heated to 80° C., followed by filtration to get the filtered cake. The cake is then washed for three times using water at 85° C.
[0096] 4. The crystallization process of the tridecanedicarboxylic acid.
[0097] 1) The filtering cake of the washed tridecanedicarboxylic acid is re-suspended in water with mass of five-folds of that of the cake mass. The mixture is then heated to 124˜126 ° C. using a pressure vessel(GSHA-2 (2L), Henghua Chemical Plant, Weihai, P.R. China), and maintained at the temperature for 20-30 minutes.
[0098] 2) The temperature of the mixture is dropped continuously and slowly to the room temperature at a rate of 10° C. per hour. Tridecanedicarboxylic acid will be crystallized during the temperature dropping process;
[0099] 3) The crystallized tridecanedicarboxylic acid is obtained by centrifuging. Some float on the aqueous surface of the mixture, which contains monocarboxylic acid, is separated and removed using this method;
[0100] 4) The residual moisture is dried in a vacuum oven; and the purified tridecanedicarboxylic acid is procured.
[0101] The obtained tridecanedicarboxylic acid is 218.2 g in total, and the purity is 98.8%, the yield of product is 87.8%.
EXAMPLE 4
[0102] The method of the example 3 is same with the method of example 4, the difference is only that the raw material is 160 g methyl hexadecanoate, and the final product is 121.5 g tridecanedicarboxylic acid, and the purity is 98.6%, the yield of product is 91.68%.
[0103] The properties of the product of example 1-4 are shown in Table 2. And the test of purity is the method of high performance liquid chromatography (shown in FIGS. 2 a and 2 b ).
[0000]
TABLE 2
sodium
palmitate
methyl
nC 12
nC 13
(0.5M)
hexadecanoate
MW
170
184
278
270
Raw material (g)
150
150
278
160
Mass of pure diacid (g)
138.2
124.1
218.2
121.5
Mass of total acid a (g/L)
187
177
248.5
132.7
Rate of raw material
68.1
62.4
76.3
71.7
conversion b (%)
Yield of product (%) c
95.2
92.8
87.8
91.6
Purity of the rude product
87
87
83
85
(%) d
Purity of the crystallization
99.2
98.8
98.6
98.6
product d (%)
a Mass of total acid, which is tested using the titration method with NaOH (CN 1130685, example 1);
b Mol conversion rate, i.e. the mol of the final product diacid/the mol of the raw material × 100%;
c the mass of the total acid/the mass of the acid in the fermentation supernatant × 100%;
d the test method is high performance liquid chromatography. | An organic solvent free method for purifying and refining of a long-chain dicarboxylic acid or a salt thereof is disclosed. This method avoids problems caused by organic solvents which have been used in the purifying process of the prior art. This method reduces effectively the content of such impurities as proteins and coloring materials in the product. The purity of the crystallized long-chain dicarboxylic acid product is greater than 99 wt %. | 2 |
BACKGROUND OF THE INVENTIONS
[0001] 1. Field of Inventions
[0002] The present inventions relate generally to gas pilots and, more particularly, to the oxygen level detection systems associated with gas pilots.
[0003] 2. Description of the Related Art
[0004] Gas pilot systems are associated with a wide variety of gas fueled devices. Such devices include, but are not limited to, vented gas heaters, which include pipes or conduits that are used to vent exhaust to the atmosphere, vent-free gas heaters, vented and vent-free gas log heater, vented and vent-free fireplace systems, water heaters, vented and vent-free stoves, and ovens. The most common types of gas fuel are natural gas and propane. A gas pilot system typically includes an ignition device, such as an electrode, and a pilot having a small nozzle. A pilot flame is formed when gas from the nozzle is ignited by the ignition device. The pilot flame is then used to ignite the gas that is supplied to the burner(s) of the gas fueled device during use.
[0005] The level of oxygen in the air is typically about 20.9%. It is important that the oxygen level in a room in which a gas fueled device is used remain at or near 20.9%, both for proper combustion and safety purposes. An adequate supply of fresh air will maintain the oxygen level at or near the desired level. In buildings with loose structures, such as houses made of wood, an adequate supply of fresh air will enter via wall spaces as well as door and window frames. Other buildings are more tightly sealed. Here, steps should be taken to insure that fresh air is supplied.
[0006] Unfortunately, some rooms do not receive an adequate supply of fresh air. Thus, for safety purposes, many gas fueled devices include an oxygen depletion sensor system (“ODS system”) which will automatically shut off the flow of gas to the pilot and burner when the oxygen level in the air drops below a predetermined “unsafe” level (typically below about 18.5%). The ODS systems monitor the pilot flame because the position of the pilot flame relative to the pilot nozzle is indicative of the oxygen level in the room.
[0007] Referring to FIGS. 1A to 1 C, conventional ODS systems employ a thermocouple TC to detect the presence of a pilot flame F when it is in the “normal” oxygen level position (oxygen level greater than or equal to 21%) illustrated in FIG. 1A or the “relatively low” oxygen level position (oxygen level between 18.5% and 19.2%) illustrated in FIG. 1B. In either case, gas will continue to flow to the pilot and burner because the voltage generated by the thermocouple TC, and received by the ODS system controller, will be within an allowable range. When the oxygen level drops to an “unsafe” level (oxygen level below 18.5%), the pilot flame F will move to the location illustrated in FIG. 4C. Here, the pilot flame will not be in contact with the thermocouple TC or substantially close to thermocouple TC. As a result, the temperature of the thermocouple TC will drop, as will the voltage produced thereby. The voltage drop will cause the ODS system to cut off the supply of gas to the pilot and burner. As illustrated in U.S. Pat. No. 5,807,098 to Deng, which is incorporated herein by reference, some ODS systems also include a second thermocouple that is used to generate a warning when the pilot flame moves to the “relatively low” oxygen level position.
[0008] Although conventional ODS systems are generally quite useful, the inventor herein has determined that there are also certain disadvantages associated therewith. Most notably, when the level of oxygen in a room is dropping, the pilot flame F will often first bounce back and forth between the “normal” position illustrated in FIG. 1A and the “relatively low” position illustrated in FIG. 1B, and then bounce back and forth between the “relatively low” position illustrated in FIG. 1B and the “unsafe” position illustrated in FIG. 1C. This can go on for a significant period of time. The pilot flame F will, for example, often bounce back and forth between the “relatively low” position and the “unsafe” position for 15 seconds and, during this time, the temperature at the thermocouple TC will not drop to a level low enough to cause the ODS system to cut off the supply of gas to the pilot and burner. As a result, the inventor herein has determined that the conventional methods of monitoring the pilot flame introduce unnecessary delays into the operation of conventional ODS systems.
SUMMARY OF THE INVENTIONS
[0009] A pilot system in accordance with one embodiment of a present invention includes a pilot having a nozzle and a light sensor adjacent to the nozzle. The light sensor determines whether or not the pilot flame is in a predetermined position relative to the nozzle. In a preferred implementation, the light sensor determines when the pilot flame is not in either of the “normal” oxygen level and “relatively low” oxygen level positions, i.e. when the pilot flame is in the “unsafe” oxygen level position.
[0010] There are a number of advantages associated with such a pilot system. Most notably, the light sensor is capable of detecting movement of the pilot flame the instant that the pilot flame first moves to the “unsafe” oxygen level position, even if it quickly bounces back to the “relatively low” oxygen level position. ODS systems employing the present pilot system will, therefore, be able to make an “unsafe” oxygen level determination much more quickly than ODS systems that employ a conventional thermocouple-based pilot flame monitoring arrangement. As a result, ODS systems employing the present pilot system will also be able to, for example, cut off the supply of gas to a pilot and burner much faster than ODS systems that employ a conventional thermocouple-based pilot flame monitoring arrangement.
[0011] The above described and many other features and attendant advantages of the present inventions will become apparent as the inventions become better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Detailed description of preferred embodiments of the inventions will be made with reference to the accompanying drawings.
[0013] [0013]FIG. 1A is a side view of a conventional pilot system and oxygen depletion sensor with th pilot flame in the “normal” oxygen level position.
[0014] [0014]FIG. 1B is a side view of the conventional pilot system and oxygen depletion sensor illustrated in FIG. 1A with the pilot flame in the “relatively low” oxygen level position.
[0015] [0015]FIG. 1C is a side view of the conventional pilot system and oxygen depletion sensor illustrated in FIG. 1A with the pilot flame in the “unsafe” oxygen level position.
[0016] [0016]FIG. 2A is a side view of a pilot system and oxygen depletion sensor in accordance with a preferred embodiment of a present invention with the pilot flame in the “normal” oxygen level position.
[0017] [0017]FIG. 2B is a side view of the pilot system and oxygen depletion sensor illustrated in FIG. 2A with the pilot flame in the “relatively low” oxygen level position.
[0018] [0018]FIG. 2C is a side view of the pilot system and oxygen depletion sensor illustrated in FIG. 2A with the pilot flame in the “unsafe” oxygen level position.
[0019] [0019]FIG. 3 is a section view of a mixing chamber in accordance with a preferred embodiment of a present invention.
[0020] [0020]FIG. 4 is a top view of a portion of the pilot system and oxygen depletion sensor illustrated in FIG. 2A.
[0021] [0021]FIG. 5 is a perspective view of a heater in accordance with a preferred embodiment of a present invention.
[0022] [0022]FIG. 6 is a partially exploded view of a propane gas heating assembly that may be used in conjunction with the heater illustrated in FIG. 5.
[0023] [0023]FIG. 7 is a diagram of a gas fueled system in accordance with a preferred embodiment of a present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The following is a detailed description of the best presently known modes of carrying out the inventions. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the inventions.
[0025] As illustrated for example in FIGS. 2A, 3 and 4 , a pilot system 10 in accordance with a preferred embodiment of a present invention includes a pilot 12 having a gas/air mixing chamber 14 and a nozzle 16 . Gas G enters the mixing chamber 14 through a small gas orifice 18 , while air A enters the mixing chamber through a pair of small air orifices 20 . The gas/air mixture G/A exits the mixing chamber 14 through an outlet orifice 22 . Mixing continues as the gas/air mixture G/A travels through a tube 24 to the nozzle 16 . The gas G in the gas/air mixture G/A is ignited by the L-shaped electrode 26 of an ignitor 28 to create the pilot flame F. The inlet and outlet orifices 18 and 22 are preferably formed from a relatively hard material. In a preferred implementation, the orifices are formed in a ruby or other hard precious stone that is mounted in a copper frame.
[0026] The size of the orifices 18 and 20 depends on the fuel being used. For example, when the fuel is natural gas supplied at a pressure of 6 inches of mercury, the orifice 18 is approximately 0.38 mm in diameter and the orifice 18 is approximately 0.46 mm in diameter when the natural gas is supplied at a pressure of 3 inches of mercury. In both cases, the orifices 20 are each approximately 3 mm in diameter. The orifice 18 is approximately 0.22 mm in diameter and the orifices 20 are each approximately 3.2 mm in diameter when the fuel is liquid propane gas supplied at about 8 to 11 inches of mercury. The outlet orifice 22 is approximately 4 mm. The outlet pressure should be about 8 to 11 inches of mercury when the fuel is liquid propane gas and about 3 to 6 inches of mercury when the fuel is natural gas.
[0027] Mixing the gas and air in the manner described above is advantageous because it insures that the level of oxygen in the ambient air will be accurately represented by the position of the pilot flame F, thereby increasing the accuracy of the ODS system described below. Accuracy of the ODS system may also be augmented by controlling movement of the pilot flame F through use of the relationship between the diameter of the pilot nozzle 16 , the fuel pressure, the distance of the electrode 26 from the nozzle as well as the location of the electrode relative 26 to the nozzle centerline, and the level of oxygen in the air. In a pilot system for use in conjunction with a propane gas heater such as that illustrated in FIGS. 5 and 6, the diameter of the pilot nozzle 16 is approximately 0.23 mm (+0.005 mm) and the gas pressure is between 8 and 11 inches of mercury. The downwardly extending portion of the L-shaped electrode 26 is offset with respect to the centerline of the pilot nozzle 16 by 3.00 mm and is spaced approximately 3.50 mm from the nozzle. Such an arrangement reduces the speed of gas flow, thereby increasing the duration and effectiveness of gas/air mixing, and also reduces the tendency of the pilot flame F to bounce around, as compared to conventional S-shaped electrodes.
[0028] The exemplary pilot system 10 illustrated in FIGS. 2A, 3 and 4 also includes an oxygen depletion sensor that may be used in an ODS system in the manner described below with reference to FIGS. 6 and 7. The oxygen depletion sensor is preferably a light sensor that senses light from the pilot flame F. Any suitable light sensor may be employed so long as it is capable of detecting the presence and absence of light emitted by the pilot flame F. In the preferred embodiment, the pilot system 10 is provided with an infrared sensing device 30 having a sensing element 32 that is positioned adjacent to the pilot nozzle 16 and pilot flame F. A suitable infrared sensing device is manufactured by Shanghai Infrared Appliances Co., located in Shanghai, China. The pilot flame F generates infrared electromagnetic radiation (i.e.electromagnetic radiation with wavelengths between 750 nanometers and 1 millimeter) which is sensed by the sensing element 32 when the pilot flame is in the “normal” oxygen level position illustrated in FIG. 2A and, in the illustrated embodiment, in the “relatively low” oxygen level position illustrated in FIG. 2B. The infrared radiation causes the sensing element 32 to generate a flame signal which indicates that the flame is in the normal position. Another example of a suitable light sensor is one that senses visible light (not shown), such as those produced by China Wuxi Light Appliances Co, located in Wuxi, China. In the preferred embodiment, the instant that the pilot flame F moves beyond the “relatively low” oxygen level position (oxygen level between 18.5% and 19.2%) illustrated in FIG. 2B to the “unsafe” level position (oxygen level below 18.5%) illustrated in FIG. 2C, the sensing device 30 will stop generating a flame signal which indicates that the pilot flame is in an allowable position. The signal from the sensing device may drop to zero, or simply to a level lower than the expected level, when the pilot flame F moves from the “normal” or “relatively low” oxygen level position to the “unsafe” oxygen level position. Thus, even in those instances where the pilot flame F jumps back and forth between the “relatively low” and “unsafe” oxygen level positions, the present sensing device 30 will immediately indicate that the oxygen level has dropped to an “unsafe” level because it will fail to produce the expected flame signal the first time that the pilot flame moves out beyond of the “relatively low” position to the “unsafe” position.
[0029] As illustrated in FIGS. 2A and 4, the exemplary pilot system 10 may also be provided with a light shield 34 that is positioned above the nozzle 16 around the area that will be occupied by the pilot flame F when the oxygen level is “normal.”The light shield 34 , which is preferably opaque, non-reflective and formed from metal, includes a slot 36 that faces the sensing element 32 . The light shield 34 prevents the sensing element 32 from being effected by stray light that could result in the expected flame signal when the flame is actually in the “unsafe” oxygen level position. As such, the sensing element 32 will only be effected by the infrared electromagnetic radiation from the pilot flame F which passes through the slot 36 when the pilot flame is in the “normal” and “relatively low” oxygen level positions. In the illustrated embodiment, the light shield 34 is about 7.2 mm in diameter and about 10 mm in length, while the slot 36 is about 3.6 mm wide.
[0030] In an alternative embodiment (not shown), the components may be reconfigured such that the sensing device 30 will stop generating a signal which indicates that the pilot flame F is in an allowable position the instant that the pilot flame F moves out of the “normal” oxygen level position to either the “relatively low” oxygen level position or the “unsafe” oxygen level position. For example, the light shield 34 could be provided with a small hole that faces the sensing element 32 in place of the slot 36 in order to substantially reduce the amount of light from the pilot flame F that will reach the sensing element when the pilot flame moves to the “relatively low” oxygen level position.
[0031] The exemplary pilot system 10 is also provided with a bracket system 38 that fixes the positions of the various elements of the pilot system relative to one another. Referring more specifically to FIGS. 2B and 2C, the exemplary bracket system 38 includes a L-shaped main bracket 40 having a first portion 42 that is mounted on the pilot 12 adjacent to the nozzle 16 . The light shield 34 is supported by the first portion 42 . The ignitor 28 and sensing device 30 are mounted on a second portion 44 of the main bracket 40 and are fixed in place by a clamp 46 . The clamp 46 may be secured to the main bracket 40 with a screw 48 or other suitable fastening device. A pair of mounting apertures 50 and 52 are formed in the main bracket 40 so that the pilot system 10 may be easily mounted within a gas fueled device. In the illustrated embodiment, the end of the sensing element 32 is about 20 to 22 mm from the nozzle 16 and about 26 to 36 mm above the nozzle (measured with the system 10 oriented such that the pilot 12 extends vertically).
[0032] Although not so limited, heaters are one example of a gas fueled device in accordance with the present inventions. An exemplary heater 100 is shown in FIG. 5. Such a heater may be fueled by natural gas, propane gas or other appropriate fuels. The exemplary heater 100 includes a housing 102 mounted on a base 104 . The housing 102 includes a heating chamber 106 which contains a plurality of heat emitting ceramic infrared burner plaques 108 and is covered by a grill 110 . The housing 102 also includes a plurality of air circulation vents 112 and 114 , as well as a pair of handles 116 . Air enters the housing through vent 112 and exits through the heating chamber grill 110 and the vent 114 .
[0033] The heater controls are located on the top portion of the housing 102 in the exemplary heater 100 . These controls include an ignition knob 118 , a temperature setting knob 120 that is used when the heater is in the thermostatic control mode, and a burner control knob 122 that is used to select the number of burners to which fuel will be supplied. The exemplary ignition knob 118 includes OFF, IGNITE, PILOT and ON settings. The temperature setting knob 120 includes a plurality of numbered settings, each corresponding to a desired amount of heat output.
[0034] As shown by way of example in FIG. 6, a propane gas-fueled heating assembly that may be used in conjunction with the housing 102 shown in FIG. 5 includes five burners 124 , each of which consists of an infrared ceramic plaque 108 that is secured to a corresponding burner box 126 . The number of burners may, however, be increased or decreased to suit particular applications. An upper burner deflector bracket 128 and lower burner deflector bracket 130 are also shown. Propane gas is supplied to the burners and pilot system in the following manner.
[0035] Referring to FIGS. 6 and 7, the gas enters the heating assembly through a pressure regulator 132 and an inlet pipe 134 . From there, it enters a thermostat and valve control system 136 . The exemplary control system 136 includes an electronic controller 138 such as a control circuit, microcontroller, microprocessor or other suitable control apparatus. The ignition knob 118 and temperature setting knob 120 are connected to the controller 138 . No gas will pass beyond the control system 136 when the ignition knob 118 is set to the OFF mode. To place the heater in the pilot mode, the ignition knob 118 is moved from the from the OFF position, past the IGNITE position to the PILOT position. The controller 138 will cause a valve 139 to open and allow gas to pass through a gas line 140 to the pilot 12 . The ignitor 28 , which is connected to the control system 136 by a wire 142 , ignites the gas/air mixture to form the pilot flame F. As noted above, the pilot flame F is monitored by the sensing device 30 . Signals from the sensing device 30 are provided to the control system 136 by a wire 143 .
[0036] Suitable commercially available thermostat and valve control systems include Mertik Maxitrol GmbH (located in Thale, Germany) Model No. GV31-A 1 A 2 A 9 HOI; Copreci, S. Coop. (located in Aretxabaleta, Spain) Model Nos. VT-23100/13 and VT-23100/ET093-01; SIT Ia precisa, s.p.a (located in Padova, Italy) Model Nos. EUROSIT 0.630.535 and EUROSIT 0.630.545; and Nan Jia Electric & Gas Products Co. Ltd. (located in Nan Jing, China) Model Nos. WHED09001, WHEF09002, WEEF09004, WEED09003 and WEHE09005.
[0037] After the pilot flame F is lit and appropriate signals from the sensing device 30 are received, the controller 138 will maintain valve 139 in the open position and also cause valve 141 to open, thereby allowing gas to be supplied to the burners through a gas line 144 and a gas control valve 146 . The amount of gas supplied to the burners 124 is mechanically regulated by the thermostat and valve control system 136 and valve 141 and is equal to that necessary to maintain the temperature specified by the temperature setting knob 120 . The temperature is monitored by a thermocouple 148 which is connected to the control system 136 by a line 150 . The burner control knob 122 in the exemplary embodiment has five settings, OFF, PILOT/IGNITE, LOW, MEDIUM and HIGH, each of which corresponds to a control valve 146 state. No gas is supplied to the burners 124 by the control valve 146 when the control knob 122 is set to OFF or PILOT/IGNITE. When the control knob 122 is set to LOW, MEDIUM or HIGH, gas will be supplied to one, three or five of the burners, respectively, through gas lines 152 , 154 and 156 .
[0038] It should be noted that if, for example, a three burner design is employed, then the corresponding progression could be one, two or three burners. It should also be noted that heaters in accordance with the present invention may also be cond in such a manner that the burner control knob 122 and control valve 146 are both eliminated. When such a configuration is employed, all of the burners will be used whenever the heater is in operation and the amount of gas supplied to the burners will be controlled by the thermostat control valve. Ignition functions may be handled by an ignition switch.
[0039] Turning to oxygen level detection, the sensing device 30 and controller 138 form an ODS system that may operate in the following manner. As noted above, the instant that the pilot flame F moves beyond the “relatively low” oxygen level position (oxygen level between 18.5% and 19.2%) illustrated in FIG. 2B to the “unsafe” oxygen level position (oxygen level below 18.5%) illustrated in FIG. 2C, the sensing device 30 will stop generating a flame signal which indicates that the pilot flame is in an allowable position. The controller 138 will, as a result, immediately close the valve 139 that allows gas to pass to the pilot 12 and also close the valve 141 that allows gas to pass to the burners 124 (if the valve 141 has been opened). The heater 100 may, if desired, be provided with an audio and/or visual alarm that is triggered by the controller 138 the valves 139 and 141 are closed by the controller in response to an “unsafe” oxygen level detection.
[0040] Although the present inventions have been described in terms of the preferred embodiments above, numerous modifications and/or additions to the above-described preferred embodiments would be readily apparent to one skilled in the art. By way of example, but not limitation, the present inventions may be incorporated in heaters which do not have a thermostatic control system. The “unsafe,” “low” and “normal” oxygen level percentages discussed above may be varied if desired. The exemplary pilot system may also be incorporated into other gas fueled devices such as water heaters, stoves, ovens and other types of heaters. The pilot, sensing device and controller could also be reconfigured and repositioned such that the sensing device senses the flame when it is in the “unsafe” oxygen level position and this sensing results in closure of the gas valve(s). It is intended that the scope of the present inventions extends to all such modifications and/or additions. | A pilot system including a pilot including a nozzle and a light sensor adjacent to the nozzle. The light sensor determines whether or not the pilot flame is in a predetermined position relative to the nozzle. | 5 |
This application claims benefit from prior Provisional Application Serial No. 60/135,290, filed May 21, 1999.
This invention relates to an apparatus and method for the construction and utilization of molecular deposition domains. More specifically, this invention is a method for the construction and utilization of molecular deposition domains into a high density molecular array for identifying and characterizing molecular interaction events.
BACKGROUND
Interactions between molecules is a central theme in living systems. These interactions are key to myriad biochemical and signal transduction pathways. Messages from outside a cell travel along signal transduction pathways into the cell's nucleus, where they trigger key cellular functions. Such pathways in turn dictate the status of the overall system. Slight changes or abnormalities in the interactions between biomolecules can effect the biochemical and signal transduction pathways, resulting in inappropriate development, cancer, a variety of disease states, and even cell senescence and death. On the other hand, it can be extremely beneficial to develop reagents and effectors that can inhibit, stimulate, or otherwise effect specific types of molecular interactions in biochemical systems; including biochemical and signal transduction pathways. Reagents and effectors that effect nucleus interactions may often become very powerful drugs which can be used to treat a variety of conditions.
Current Technology
Several recent studies have shown that a scanning probe microscope “SPM” may be used to study molecular interactions by making a number of measurements. The SPM measurements may include changes in height, friction, phase, frequency, amplitude, and elasticity. The SPM probe can even perform direct measurements of the forces present between molecules situated on the SPM probe and molecules immobilized on a surface. For example, see Lee, G. U., L. A. Chrisey, and R. J. Colton, Direct Measurement of the Forces Between Complementary Strands of DNA . Science, 1994. 266: p. 771-773; Hinterdorfer, P., W. Baumgartner, H. J. Gruber, and H. Schindler, Detection and Localization of Individual Antibody antigen Recognition Events by Atomic Force Microscopy , Proc. Natl. Acad. Sci., 1996. 93: p. 3477-3481; Dammer, U., O. Popescu, P. Wagner, D. Anselmetti, H.-J. Guntherodt, and G. N. Misevic, Binding Strength Between Cell Adhesion Poteoglycans Measured by Atomic Force Microscopy . Science, 1995. 267: p. 1173-1175; Jones, v. et al. Microminiaturized Immunoassays Using Atomic Force Microscopy and Compositionally Patterned Antigen Arrays , Analy. Chem., 1998 70(7): p. 1233-1241; and Rief, M., F. Oesterhelt, B. Heymann, and H. E. Gaub, Single Molecule Force Spectroscopy on Polysaccharides by Atomic Force Microscopy , Science, 1997. 275: p. 1295-1297. The above studies illustrate that it is possible to readily and directly measure the interaction between and within virtually all types of molecules by utilizing an SPM. Furthermore, recent studies have shown that it is possible to use direct force measurement to detect changes in molecular complex formation caused by the addition of a soluble molecular species. A direct force measurement may elucidate the effect of soluble molecular species on the interaction between a molecular species on an SPM probe and a surface.
Molecular Arrays
The ability to measure molecular events in patterned arrays is an emerging technology. The deposition material can be deposited on a solitary spot or in a variety of sizes and patterns on the surface. The arrays can be used to discover new compounds which may interact in a characterizable way with the deposited material. Arrays provide a large number of different test sites in a relatively small area. To form an array, one must be able to define a particular site at which a deposition sample can be placed in a defined and reproducible manner.
There are four approaches for building conventional molecular arrays known in the art. These prior art methods include 1) mechanical deposition, 2) in situ photochemical synthesis, 3) “ink jet” printing, and 4) electronically driven deposition. The size of the deposition spot (or “domain”) is of particular importance when utilizing an SPM to scan for molecular recognition events. Current SPM technology only allows a scan in a defined area. Placing more domains in this defined area allows for a wider variety of molecular interaction events to be simultaneously tested.
Mechanical deposition is commonly carried out using a “pin tool” device. Typically the pin tool is a metal or similar cylindrical shaft that may be split at the end to facilitate capillary take up of liquid. Typically the pin is dipped in the source and moved to the deposition location and touched to the surface to transfer material to that domain. In one design the pin tool is loaded by passing through a circular ring that contains a film of the desired sample held in the ring by surface tension. The pin tool is washed and this process repeated. Currently, pin tool approaches are limited to spot sizes of 25 to 100 microns or larger. The spot size puts a constraint on the maximum density for the molecular deposition sites constructed in this manner. A need exists for a method that allows for molecular domains of smaller dimensions to be deposited.
In situ photochemical procedures allow for the construction of arrays of molecular species at spatial addresses in the 1-10 micron size range and larger. In situ photochemical construction can be carried out by shining a light through a mask. Photochemical synthesis occurs only at those locations receiving the light. By changing the mask at each step, a variety of chemical reactions at specific addresses can be carried out. The photochemical approach is usually used for the synthesis of a nucleic acid or a peptide array. A significant limitation of this approach is that the size of the synthetic products is constrained by the coupling efficiency at each step. Practically, this results in appreciable synthesis of only a relatively short peptide and nucleic acid specimen. In addition, it becomes increasingly improbable that a molecule will fold into a biologically relevant higher order architecture as the synthetic species becomes larger. A need exists for an alternative method for deposition of macromolecular species that will preserve the molecular formation of interest in addition to avoiding the cost of constructing the multiple masks used in this method.
Ink jet printing is an alternative method for constructing a molecular array. Ink jet printing of molecular species produces spots in the 100 micron range. This approach is only useful for printing a relatively small number of species because of the need for extensive cleaning between printing events. A key issue with ink jet printing is maintenance of the structural/functional integrity of the sample being printed. The ejection rate of the material from the printer results in shear forces that may significantly compromise sample integrity. A need exists for a method that will retain the initial structure and functional aspects of the deposition material and that will form smaller spots than are possible with the above ink jet method.
Electronic deposition is yet another method known for the construction of molecular arrays. Electronic deposition may be accomplished by the independent charging of conductive pads, causing local electrochemical events which lead to the sample deposition. This approach has been used for deposition of DNA samples by drawing the DNA to specific addresses and holding them in a capture matrix above the address. The electronic nature of the address can be used to manipulate samples at that location, for example, to locally denature DNA samples. A disadvantage of this approach is that the address density and size is limited by the dimensions of the electronic array.
A need exists for a molecular deposition technique that will allow for smaller deposition spots (domains). Smaller deposition domains allow for an array to be constructed with a greater density of domains. More domains further allow for a wider variety in the deposition material to be placed on the same array, allowing a user to search for more molecular interaction events simultaneously.
A further need exists for the ability to place these spots at a defined spatial address. Placing the domains at defined spatial addresses allows the user to know exactly what deposition material the SPM is scanning at any given time.
Furthermore, a need exists for a method to make deposition domains with large molecular weight samples that also retains the desired chemical formation. Finally, a need exists for the efficient construction of these molecule domains into an array.
Molecular Detection
All of the above examples are further limited because they require some type of labeling of the deposition sample for testing. Typical labeling schemes may include fluorescent or other tags coupled to a probe molecule. In a typical molecular event experiment, an array of known samples, for example DNA sequences, will be incubated with a solution containing a fluorescent indicator. In the DNA example this would be fluorescently or otherwise labeled nucleic acids, most often a single stranded DNA of an unknown sequence. Specific sequence elements are identified in the DNA sample by virtue of the hybridization of the label to addresses containing known sequence elements. This process has been used to screen entire ensembles of expressed genes in a given population of cells at a particular time or under a particular set of conditions. Other labeling procedures have also been employed, including RF (radio frequency) labels and magnetic labels. These methods are less frequently used, however, than the fluorescent label methods desired above. All of these labels hinder experiments with extra steps, reagents, and in some cases, risk.
Other methods for the detection of the interactions of molecules on a molecular array include inverse cyclic voltametry, capacitance or other electronic changes, radioactivity (such as with isotopes of phosphorous), and chemical reactions. In virtually all cases, some form of labeling of the probe molecule that is added to the array is required. This is a significant limitation of current arrays. A need exists for a method that does not require this extra labeling step.
Scanning Probe Microscopy
A wide variety of SPM instruments are capable of detecting optical, electronic, conductive, and other properties. One form of SPM, the atomic force microscope (AFM), is an ultra-sensitive force transduction system. In the AFM, a sharp tip is situated at the end of a flexible cantilever and scanned over a sample surface. While scanning, the cantilever is deflected by the net sum of the attractive and repulsive forces between the tip and sample. If the spring constant of the cantilever is known, the net interaction force can be accurately determined from the deflection of the cantilever. The deflection of the cantilever is usually measured by the reflection of a focused laser beam from the back of the cantilever onto a split photodiode, constituting an “optical lever” or “beam deflection” mechanism. Other methods for the detection of cantilever deflection include interferometry and piezoelectric strain gauges.
The first AFMs recorded only the vertical displacements of the cantilever. More recent methods involve resonating the tip and allowing only transient contact, or in some cases no contact at all, between it and the sample. Plots of tip displacement or resonance changes as it traverses a sample surface are used to generate topographic images. Such images have revealed the three dimensional structure of a wide variety of sample types including material, chemical, and biological specimens. Some examples of the latter include DNA, proteins, chromatin, chromosomes, ion channels, and even living cells.
In addition to its imaging capabilities, the AFM can make extremely fine force measurements. The AFM can directly sense and measure forces in the microNetwon (10 −6 ) to picoNewton (10 −12 ) range. Thus, the AFM can measure forces between molecular pairs, and even within single molecules. Moreover, the AFM can measure a wide variety of other forces and phenomena, such as magnetic fields, thermal gradients and viscoelasticity. This ability can be exploited to map force fields on a sample surface, and reveal with high resolution the location and magnitude of these fields, as in, for example, localizing complexes of interest located on a specific surface.
Direct Force Measurement
To make molecular force measurements, the AFM probe is functionalized with a molecule of interest. This bio- or chemi-active probe is then scanned across the surface of interest. The molecule tethered to the probe interacts with the corresponding molecule or atoms of interest on the surface being studied. The interactions between the molecule fnctionalized on the probe and the molecules or atoms on the surface create minute forces that can be measured by displacement of the probe. The measurement is typically displayed as a force vs. distance curve (“force curve”).
To generate a force curve, the tip or sample is cycled through motions of vertical extension and retraction. Each cycle brings the tip into contact with the sample, then pulls the tip out of contact. The displacement of the cantilever is zero until the extension motion brings the tip into contact with the surface. Then the tip and sample are physically coupled as the extension continues. The physical coupling is the result of hard surface contact (Van der Waals interactions) between the probe and the surface. This interaction continues for the duration of the extension component of the cycle. When the cycle is reversed and the tip retracted, the physical contact is broken. If there is no attractive interaction between the tip and sample the tip separates from the sample at the same position in space at which they made contact during extension. However, if there is an adhesive interaction between the tip and sample during retraction, the cantilever will bend past its resting position and continue to bend until the restoring force of the cantilever is sufficient to rupture the adhesive force.
In the case of extendable molecular interactions, the distance between the tip and surface at which a rupture is observed corresponds to the extension length of the molecular complex. This information can be used to measure molecular lengths and to measure internal rupture forces within single molecules. In a force curve an adhesive interaction is represented by an “adhesion spike.” Since the spring constant of the probe is known, the adhesive force (the unbinding force) can be precisely determined. Upon careful inspection of a typical adhesion spike, many small quantal unbinding events are frequently seen. The smallest unbinding event that can be evenly divided into the larger events can be interpreted as representing the unbinding force for a single molecular pair.
The spectra produced by these binding events will contain information about the coupling contacts holding the molecules together. Thus, it is possible to interpret the signature generated by a mechanical denaturation experiment with regard to the internal structure of the molecule. An SPM can further utilize height, friction, and elasticity measurements to detect molecular recognition events. Molecular recognition events are when one molecule interacts with another molecule or atom in, for example, an ionic bond, a hydrophobic bond, electrostatic bond, a bridge through a third molecule such as water, or a combination of these methods.
In an alternative approach, the AFM probe is oscillated at or near its resonance frequency to enable the measurement of recognizance parameters, including amplitude, frequency and phase. Changes in the amplitude, phase, and frequency parameters are extremely sensitive to variations in the interaction between the probe and the surface. If the local elasticity or viscosity of the surface changes as a result of a molecular recognition event, there is a shift in one or more of these parameters.
Others have reported using AFMs and STMs for the deposition of materials. One report is from Chad Mirkin (Northwestern University) in which he used an AFM to write nanometer scale molecule features with short alkane chains. Hong, S., J. Zhu, and C. A. Mirkin, Multiple Ink Nanolithography: Toward A Multiple - Pen Nano - Plotter , Science. 1999, p. 523-525. A need exists, however, for a molecular domain deposition method that is not limited to short chain length molecules. A need exists for a method for depositing longer chain length macromolecules that does not change or hinder the formation of the deposited molecule.
A need exists for an improved apparatus and method for utilization in the detection of molecular interaction events. A need exists for a method for the creation of small, sub-micron scale molecular domains at defined spatial addresses. This apparatus should enable the user to test for a variety of different types of events in a spatially and materially efficient manner by facilitating the deposition, exposure, and scanning of molecular domains to detect a resultant molecular interaction event. Furthermore, an apparatus is needed that enables the placement of a large number of molecular domains in a relatively small area.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the method of forming a deposition domain.
FIG. 2 is a block diagram of the method of forming an array and utilizing the same.
FIG. 3 is a side view of the deposition device used with the present invention.
FIG. 4 is a side view of the deposition device and the microspheres of the present invention.
FIG. 5 is a side view of a microsphere attached to a deposition device.
FIG. 6 is an alternative attachment of the microsphere to the deposition device.
FIG. 7 a is a side view of the deposition device before loading the deposition material on it.
FIG. 7 b is a side view of a capillary bridge between the deposition material and the microsphere during loading of the deposition material
FIG. 8 a is a side view of a microsphere with deposition material loaded on the microsphere.
FIG. 8 b is a side view of a capillary bridge between the microsphere and a surface druring the deposition of a deposition domain.
FIG. 9 is a side view of a deposition domain on an array just after the microsphere has been withdrawn.
FIG. 10 is a perspective view of an array of the present invention.
FIG. 11 is an outline view of an example scan of an array after exposure to a target medium.
SUMMARY
A method for the construction of a molecular deposition domain on a surface, comprising, providing a surface, depositing a deposition material on a deposition device, and depositing the deposition material on the surface using said deposition device, forming a molecular deposition domain smaller than one micron in total area.
Another embodiment comprises method for constructing an array of molecular deposition domains including the steps of providing a surface, providing an at least one deposition material, depositing a first deposition material on a deposition device, depositing the first deposition material on the surface in a known position, forming a first molecular deposition domain smaller than one micron in total area, cleaning the deposition device, and repeating the above steps with an at least one other deposition material, creating an array of two or more deposition domains on said surface.
Yet another embodiment comprises a method for detecting a target sample, the method comprising, forming a molecular array on a surface, the molecular array including an at least one molecular deposition domain, said at least one molecular deposition domain smaller than one micron in total area, exposing the surface to a sample medium, the sample medium containing one or more target samples which cause a molecular interaction event in one or more of the at least one deposition domain, and scanning the surface using a scanning probe microscope to detect the occurrence of the molecular interaction event caused by the target sample.
A still further embodiment comprises a molecular array for characterizing molecular interaction events, comprising a surface, and an at least one molecular deposition domain deposited on said surface wherein the spatial address of the domain is less than one micron in area.
Another embodiment comprises a method for the processing of multiple arrays including forming an array in a substrate, the array comprising a plurality of deposition domains formed of a deposition material, exposing the array to one or more materials which contain an at least one sample molecule that causes a molecular interaction event with one or more of the deposition samples, and scanning the array utilizing a scanning probe microscope to characterize the molecular interaction events that have occurred between the target sample and the deposition material.
One object of this invention is the construction of relatively small molecular domains with large molecular species.
Another object of this invention is the construction of molecular arrays comprised of molecular domains, each containing as little as a solitary molecule.
Another object of the present invention is an apparatus and method for the creation of a molecular array comprised of one or more molecular domains, each with an area smaller than one micron.
Another object of this invention is the utilization of molecular domain arrays without having to perform a labeling step to allow for the detection of a molecular event.
Another object of this invention is a molecular deposition array that has an effective screening limit at the single molecule level.
Another object of the present invention is a method for using an AFM in a high throughput format to detect and evaluate interactions between molecules.
Another object of this invention is the placement of molecular deposition domains at a defined spatial address.
DETAILED DESCRIPTION
I. Definitions
The following are some definitions that may be helpful in understanding the description of the present invention. These are intended as general definitions and should in no way limit the scope of the present invention to those terms alone, but are put forth for a better understanding of the following description.
A. Deposition Material: This is a selected sample placed on a surface that can be recognized and/or reacted with by a target sample. The deposition material will ideally have a change inflicted upon it by one or more target samples that can be detected by later scanning with an SPM. This is the known material placed in the domain. Examples of deposition materials include, but are not limited to, biomolecules, proteins, a variety of chemicals, DNA, RNA, antibodies, or any other substance recognized by one skilled in the art which may have usefulness within the teaching of the present invention.
B. Deposition Domain: A deposition domain is a spot on a surface upon which a deposition material is placed. The domain may be of any size, shape, and pattern and may contain as little as one molecule of the deposition material. These deposition domains may alternatively be referred to as “spots” or “points.” The boundary of the domain is defined by the boundary of the material placed therein.
C. Array: Alternatively referred to using the term “array,” “bioarray,” “molecular array,” or “high density molecular array.” The term array will be used to describe the one or more molecular domains deposited on the surface.
D. Target Sample: A substance with a particular affinity for one or more deposition domains.
These target samples may be natural or man-made substances. The target samples may be known or unknowns present in a solution, gas, or other medium. These target samples may bind to the deposition domain or simply alter the deposition in some other cognizable way. Examples of target samples may include, but are not limited to, antibodies, drugs, nucleic acids, proteins, cellular extracts, antibodies, etc. The target medium may likewise be artificially made or, in the alternative, a biologically produced product.
E. AFM: As noted above, AFM's are a type of scanning probe microscope. The AFM is utilized in the present invention as an example of an SPM. The invention, however, is not limited for use with one specific type of AFM, but can also be incorporated for use with SPM's of various makes, models, and technological improvements.
F. Deposition Device: The deposition device of the following description is a modified AFM probe and tip. The basic probe and tip of the AFM is well known to one reasonably skilled in the art. The modified probe and tip that is the deposition device of the present invention may alternatively be referred to herein as “tip,” “probe tip,” or “deposition device.” Other deposition devices can be substituted by one reasonably skilled in the art, including the use of a dedicated deposition device manufactured for the express purpose of sample deposition.
II. General
The apparatus and method of the present invention allows for the placement of an at least one deposition sample in an at least one molecular deposition domain forming an array. The method of creating the present invention deposition domain may result in deposition domains smaller than one micron in total area. Furthermore, this method allows the deposition of relatively large molecular species, as large as 1 kilodalton and larger, without shearing or changing the molecular formation. This array can be exposed to a sample medium that may contain a target sample, the presence of which may be ascertained and characterized by detecting molecular interaction events. The molecular interaction event detection may be performed utilizing an atomic force microscope.
The deposition domains of the present invention may be formed as small or smaller than one micron in area. The present invention allows the direct detection of molecular interaction events in the deposition domain of the array. The molecular interaction event is detected without the need for the labeling of the deposition material or of the target sample. While labeling may still be performed for use with the present invention, the present invention does not require labeling to be utilized.
The present invention utilizes a scanning probe microscope to interrogate the various deposition domains of the present invention array. As the probe is scanned over a surface the interaction between the probe and the surface is detected, recorded, and displayed. If the probe is small and kept very close to the surface, the resolution of the SPM can be very high, even on the atomic scale in some cases.
In the present embodiment, an AFM may be used as the deposition tool, but this does not exclude other types of SPM's being used in alternative embodiments. An unmodified AFM probe has a sharp point with a radius of curvature that may be between 5 and 40 nm. The method herein uses a microfabricated deposition device with an apical radius on the order of 10-50 nm. Due to the small radius of curvature of the deposition device used herein, the spot size generated by the present method can range from larger spots to as small as 0.2 microns or smaller. The difficulties with the prior art method need for labeling, such as with radioactivity, fluorescence, enzymatic labeling, etc., are also avoided.
As one reasonably skilled in the art will appreciate, the molecular material deposited by the present invention may be of almost any size and type. The following materials and methods are not intended to exclude other materials that may be compatible with the present invention, however, the present example is given for better understanding of the scope of the present invention.
Surface Preparation
As shown in FIG. 1, block 1 , and FIG. 2, block 18 , a surface may first be provided. The deposition domains that form the array will be constructed on this surface. The surface used for the deposition of the present embodiment molecular domain should facilitate scanning by an AFM as well as facilitate the deposition of the deposition material. A surface which can accept and bind tenaciously to the deposition material may also be desired. The present embodiment utilizes a solid glass substrate. This solid glass substrate may be a glass slide well known to those reasonably skilled in the art. Other embodiments may use other substrates including, but not limited to, mica, silicon, and quartz. The present embodiment may further cover this surface with a freshly sputtered gold layer.
The ion beam sputtering of gold onto a surface is well known by those reasonably skilled in the art. Sputtering gold may produce an extremely smooth surface upon which a variety of chemistry and molecular binding may be performed. In other embodiments, the gold may be sputtered onto glass coverslips, smooth silicon, quartz or a similar flat surface. The smoothness required of the underlying substrate is a function of the sensitivity requirement of a particular test. For example, detection of a virus particle binding to antibodies on a surface requires only the smoothness of a typical glass coverslip. In contrast, detection of binding of a small ligand to a surface immobilized protein may require a supporting substrate with a surface roughness of one nanometer over an area of several microns.
In alternative embodiments, other surfaces besides that achieved by gold sputtering may be likewise utilized, such as, but not limited to, glass, Si, modified Si, (poly) tetrafluoroethylene, fnctionalized silanes, polystyrene, polycarbonate, polypropylene, or combinations thereof.
The gold of the present embodiment is sputtered onto the glass surface. This area of gold defines the boundary of the present embodiment array. The deposition material will be deposited in domains contained in this area.
Depositing the Deposition Sample on the Deposition Device
With reference to FIG. 1 block 12 , FIG. 2 block 20 , and FIG. 3, the deposition of the sample on the deposition device 40 will be described. The basic shape of the deposition device 40 is shown in FIG. 3 . Before the deposition material is formed into a molecular domain on the above surface, the deposition material must first be placed onto the deposition device 40 . The deposition device 40 of the present embodiment may be a deposition device 40 and tip 42 commonly utilized by an AFM. The present embodiment starts with a standard silicon-nitride AFM probe under the tradename “DNP Tip” produced by Digital Instruments, Inc. These probes are generally available and well known in the art. In the present embodiment, the deposition device 40 may be first placed on the deposition instrument. A Digital Instrument, Inc., Dimension 3100 may be used in the present embodiment, controlled by a standard computer and software package known in the art.
In the present embodiment, the deposition instrument may be modified with a microsphere 52 to facilitate the loading (depositing) of the deposition material 56 . While other embodiments may not utilize such a microsphere on the deposition device 40 , attaching a microsphere on the deposition device 40 allows the loading of a greater amount of deposition material upon the deposition device 40 , enabling a greater number of deposition domains 64 to be deposited before reloading with new material. Borosilicate glass spheres up to 25 microns or larger in diameter may be utilized in the present embodiment as the microspohere 52 .
First, a small amount of epoxy resin is placed upon a surface, usually glass. A standard ultraviolet activated epoxy resin, such as Norland Optical Adhesive #81, may be utilized, though those reasonably skilled in the art may fine other types of epoxies useful as well. The deposition device 40 is moved by the instrumentation and dipped slightly in the epoxy and withdrawn, retaining a small amount of the epoxy on the tip 42 . As shown in FIG. 4, on another surface 50 are placed a number of the microspheres 52 . Using the instrumentation controls, one or more of the borosilicate glass beads is touched by the end of the deposition device 40 . Because of the epoxy, the microsphere 52 sticks to the end of the deposition device 40 as it is pulled away. The deposition device 40 is then exposed to ultraviolet light to set the epoxy and permanently affix the microsphere glass bead 52 to the tip 42 of the deposition device 42 . As shown in FIG. 5 and 6, the microsphere 52 may bind to the tip 42 of the deposition device 40 in various places without affecting the present invention.
The present embodiment places one microsphere 52 on the deposition device 40 . This microsphere 52 allows the deposition device 40 to retain more of the material to be deposited on the probe while still allowing the creation of deposition domains 64 on the sub-micron scale. As noted above, as little as one microsphere 52 may be deposited on the tip in the above process. Furthermore, the surface of the microsphere 52 allows for alternative types of surface chemistry to be performed when, in alternative embodiments, the deposition material is being bonded to the surface.
The microspheres 52 used in the present embodiment are commercially available and well known in the art, ranging in size to smaller than 0.05 microns. With a smaller the microsphere 52 , a smaller deposition domain 64 may be achieved, however less sample can be deposited on the tip at any one time, slowing down the construction of the array. Modification of the deposition device 40 may also be accomplished in a number of alternative ways, including spontaneous adsorption of molecular species, chemical derivitization of the AFM tip followed by covalent coupling of the probe molecule to the tip, or the addition of microspheres to the tip which may be coupled to molecules by standard chemistry. In additional embodiments, a laser may be used to locally heat the deposition device 40 and bond microspheres (such as polystyrene spheres) by a “spot welding” technique.
As shown in FIG. 1 block 12 , and FIG. 2 block 20 , after the microsphere 52 is placed on the deposition device 40 , the deposition material 56 may be loaded on the deposition device 40 by forming a capillary bridge 60 . The deposition material 56 may be placed on a surface as shown in FIG. 7 a . This large spot of deposition material 56 can be reused a number of times, depending on the number of domains 64 that are to be created. Though not drawn to scale, FIG. 7 a shows material that may have been micro-pipetted onto a surface for loading on the deposition device 40 .
In one embodiment, the deposition device 40 may be brought into direct contact with the material 56 on the surface. In alternative embodiments, the deposition device 40 and microsphere 52 may be brought into a near proximity to the deposition material 56 on the surface and achieve the same capillary action. The exact distance between the microsphere 52 and the deposition material 56 may vary and still have the formation of a capillary bridge 60 . This depends on conditions like relative humidity, microsphere 52 size, contaminants, etc. In the present embodiment, this distance may vary between touching to several nanometers or more.
The capillary bridge 60 , shown in FIG. 7 b , may be formed by controlling the humidity by timing a blast of humid gas. Longer bursts may result in a greater amount of material to be placed on the tip. Short bursts allow for less material to be used, but must be long enough to effectively transfer deposition material 56 from the surface 62 to the deposition device 40 . The optimal parameters are determined empirically, however a typical time of exposure to the humid gas is on the order of 500 milliseconds or longer. It has also been noted that a capillary bridge 60 may be spontaneously generated when the relative humidity of the air is more than approximately 30%. In cases such as this, it may be advantageous to have a controlled dry environment or to have a stream of dry air flowing over the surface which is interrupted by the humid blast of gas which forms the capillary bridge 60 . In other embodiments, this spontaneous capillary bridge 60 can be used to deposit the deposition material 56 , though less control of the process may result.
In the present invention the humidity may be controlled by several methods known to those reasonably skilled in the art. The present embodiment incorporates a small tube and argon gas source which creates the bridge by rapidly increasing the level of humidity around the probe and the deposition material. The tube of the present embodiment may be a flexible polymer material, such at “Tygon” tubing, with an inner diameter of 0.5 to 1.0 cm. This material is readily available, but other materials that will not introduce contaminants into the deposition material would likewise suffice. The small tube must first be filled with water.
The water used in the present embodiment should be of a highly purified nature, such as purified water with a resistance of 18 megaohms or more. It should be free of particulates by filtration and is usually sterilized by filtration and or autoclaving. Additionally, an argon gas source may be positioned at one end of the tube and may be controlled by the action of a needle valve and solenoid.
The water is then drained from the tube, leaving a humid gas in the tube. When the humidity blast is desired, the solenoid is activated to pulse a discrete amount of humidified argon through the tube and over the probe 40 , deposition material 56 , and surface 62 . As shown in FIG. 7 b , the capillary bridge 60 may be formed between the surface 62 and the deposition device 40 . The deposition device 40 is then moved away from the surface 62 , leaving a small amount of the deposition material 56 on the deposition device 40 , as shown in FIG. 8 a.
As shown in FIG. 8 a , the deposition material 56 is now on the deposition device 40 . Whether the deposition material 56 adsorbs onto the microsphere's 52 surface, the pores, or some other area, may vary depending on the type of microsphere 52 and the deposition material 54 . As shown in FIG. 1 block 14 , the deposition material 56 may now be dried on the deposition device 40 . The drying may be immediate and spontaneous due to the relatively little amount of wet material on the surface of the deposition device 40 . This is, of course, dependent on the relative humidity of the surrounding air. Drying the deposition material 56 on the microsphere 56 may facilitate the deposition of the material 56 on the surface 62 as laid out in the next step. For labile samples, drying could result in inactivation, and should be avoided, but this is not the case for robust samples such as antibodies, peptides and nucleic acids.
In an alternative embodiment, the deposition tip may be loaded with the deposition material 56 by direct immersion. The tip of the probe may be immersed in a solution containing up to 50% glycerol, 0.1-5 mg/ml of the deposition sample, and a buffer-electrolyte such as Tris-HCl at pH 7.5. A small amount of the above solution may be made by standard bench chemistry techniques known to those skilled in the art. Typically 1-10 microliters are made. Because of the nature of solutions, when the probe is dipped into the solution and withdrawn a small amount of the solution will cling to the surface of the tip in a manner known to those reasonably skilled in the art. In still further embodiments, other solutions, such as 10 mM NaCl and 1 mM MgCl 2 , phosphate buffered saline, or a sodium chloride solution, may be substituted by those reasonably skilled in the art. Alternative methods for loading the deposition material 56 on the deposition device 40 include spraying, chemically mediated adsorption and delivery, electronically mediated adsorption and delivery, and either passive or active capillary filling.
In still further embodiments, other probes may also be used, for example, AFM probes lacking a tip altogether (tipless levers), may also be used. The type of probe used may impact the spatial dimensions of the deposition domain 64 and may be influenced by the choice of the deposition sample.
Depositing the Sample on the Surface
The next step in creating the deposition domain 64 and array 66 is depositing the sample on the surface. See FIG. 1 block 16 and FIG. 2 block 22 . Varying the humidity level surrounding the deposition device 40 and deposition material 56 may be taken advantage of to deposit the deposition material 56 onto the surface in a deposition domain 64 less than one micron in area. The capillary bridge 60 is illustrated by FIG. 8 b . This step may be performed in much the same way as depositing the deposition material 56 on the deposition device 40 . The degree of binding to the surface and the deposition device 40 is a function of the hydrophilicity and hydrophobicity of the two surfaces. Therefore, it may often be desirable to use deposition tools and surfaces that are free of oils and other hydrophobic contaminants to facilitate wetting of both surfaces.
Utilizing the AFM and the control computer and software, the deposition device 40 , with the deposition material 56 , may be brought into contact, or close proximity, with the deposition surface. The humid gas may then be released by activation of the solenoid. In the present embodiment the humidity is ramped up, and the capillary bridge 60 formed, for a time of approximately 400 milliseconds or less, depending on the amount of material the user wishes to deposit. The spots are on the sub-micron scale because the contact surfaces are on the order of microns or smaller and the degree of sample diffusion (which determines the final size of the deposition domain) is carefully controlled by regulating the amount and timing of the humid gas burst. When depositing the deposition sample 56 on the surface, in order to better control the length of time the capillary bridge 60 exists, a tube of dry air may be blown over the area by a solenoid in rapid succession after the humid air. This results in a very short burst of humid air, a capillary bridge 60 , and then the termination of the capillary bridge 60 , all in a very short time period. As illustrated in FIG. 9, when the deposition device 40 is withdrawn, and the bridge 60 severed, a very small amount of the deposition material 56 has been deposited on the surface 62 in a deposition domain 64 . The transfer of large macromolecules may be achieved utilizing the burst of humid gas. As will be appreciated by one reasonably skilled in the art, the capillary bridge 60 may be broken by withdrawing the deposition device 40 or by the blast of dry air.
Because of the fine control of the deposition device 40 that may be possible with the AFM instrumentation, the exact surface spot in which the deposition takes place may be noted. Noting the surface point for each deposition domain 64 may ameliorate the detection of the molecular interaction event caused by the target sample. The pattern writing program can be one that is provided by an AFM manufacturer (e.g., the Nanolithography program provided by Digital Instruments, Inc.) or it can be created in-house. In the latter case, one example is to use a programming environment such as Lab View (National Instruments) with associated hardware to generate signal pulses which control the positioning of the deposition probe.
The steps laid out above produce the deposition domain 64 of the present embodiment. Repeating these steps with one or more deposition materials 56 , FIG. 2 block 26 , produces the array 66 of the present invention. This array is shown in FIG. 10 . The number and size of the deposition domains 64 may be varied depending on the desire of the user.
One advantage to the present embodiment is the small size of the deposition domain 64 produced by the method. Furthermore, because of the manner in which the array 66 is produced, the user may be able to record and track the position of each of the particular deposition domains 64 . Finally, the above method allows the deposition of as little as a single macromolecule, which previous methods were unable to perform.
Once the array 66 has been formed, the user may desire to immediately utilize the array 66 on site, or may desire shipment of the array 66 for exposure to a sample medium at another location. The array 66 produced by the above steps may be ideal for shipment to a location, exposure, and return shipment for the scanning by an AFM.
Subsequent Depositions
In an alternative embodiment, the probe may be reloaded with a second deposition material 56 after one or more molecular domains are created with the first deposition material 56 . FIG. 2 block 26 . Using the probe with a variety of deposition materials 56 enables the creation of a number of deposition domains 64 on one surface. The different deposition materials 56 in the molecular domains that are deposited on the surface form the array 66 of the present invention. Because of the size of the molecular domain containing the deposition material 56 , the molecular domains can be placed on the surface in a an ultra high density array 66 , as shown in FIG. 10 . In the present embodiment of this invention, the pitch (the distance from the center of one domain to the center of the next domain) of the molecular domains may be as small or smaller than one micron. The array 66 produced with these small molecular domains may be easily scanned by the AFM array 66 after the array 66 is exposed to the sample medium containing the target sample in the next step. Furthermore, the small sized array 66 requires exposure to a smaller amount of the sample medium of the next step, conserving both the deposition material 56 and the medium material.
The number of times the probe may be reloaded in this alternative embodiment may be only limited by the surface size and the number of samples the user desires to deposit. As will be appreciated by those skilled in the art, this ultra high density array 66 presents a unique advantage.
Cleaning the Probe
Before the probe is reloaded with subsequent deposition samples, the probe must be cleaned. FIG. 2 block 24 . The probe of the present embodiment AFM may be cleaned in several ways. In the present embodiment, the very tip of the probe is immersed in a small aliquot of a cleaning solution. The present embodiment cleaning step utilizes pure water as the solution. A few microliters of water is pipetted onto a surface and, using the instrumentation's piezo device (which is utilized to help the AFM scan surfaces), the tip is oscillated at up to 1000 Hz or more. Resonating the probe at 1000 hertz will effectively sonicate the tip, helping to effectuate reusing the tip to deposit other deposition materials 56 .
Exposing the Array to a Sample Medium
Once a high density array 66 is formed by the present invention, the array 66 may be exposed to a sample medium. FIG. 2 block 28 . The sample medium may contain a target sample that the user has placed therein. In other types of experiments, the user may be looking for the presence of an unknown target sample, utilizing the array 66 of the present invention to test for its presence. The usefulness of such arrays 66 are well known to those reasonably skilled in the art.
The array 66 may be dipped in a solution or exposed to a gas. The solution may include, but is not limited to, waste water, biological materials, organic or inorganic user prepared solutions, etc. The exposure time of the array 66 to the medium depends on what types of molecular interaction events the user may be studying. The target sample tested for should ideally cause a readable molecular change in one or more of the deposition materials 56 of the molecular domains placed on the array 66 . These molecular changes may include binding, changes in stereochemical orientation in morphology, dimensional changes in all directions, changes in elasticity, compressibility, or frictional coefficient, etc. The above changes are what the AFM scans and reads in the next step of the present embodiment.
Molecular Event Detection
After the molecular deposition array 66 is exposed to the test medium, it may be scanned by the AFM. See FIG. 2 block 30 . Use of an AFM in this manner to characterize a material deposited on a surface is well known to those reasonably skilled in the art. The present embodiment may utilize one scan for every deposition domain 64 of the array 66 to look for changes in the recorded features of the domains. Furthermore, the AFM may look at specific portions of the array 66 using site locators. As will be appreciated by one skilled in the art, various methods may be used to undertake the scanning of the array 66 of the present invention.
After the scan is taken, the scan must be analyzed. FIG. 2, block 32 . The present embodiment utilizes the detection of changes in height at defined spatial addresses, as described by Jones et al., supra. As shown in FIG. 11, height changes only occur at those addresses containing deposition material 56 to which the target sample is capable of binding. Since the identity of the molecules at each of the sample addresses is known, this process immediately identifies those deposition materials 56 capable of binding to the target sample. In FIG. 11, point 66 shows the normal height of the deposition domain 64 as scanned by the AFM. Point 68 shows how the AFM will recognize some feature that the molecular interaction event has affected in the deposition domain 64 .
In addition, the AFM can measure whether new materials have bonded to the deposition material 56 by testing for changes in shape (morphology) as well as changes in local mechanical properties (friction, elasticity, compressibility, etc.) by virtue of changes in the interaction between the probe and the surface. The typical parameters detected by an AFM include height, torsion, frequency (the oscillation frequency of the AFM probe in AC modes of operation), phase (the phase shift between the driving signal and the cantilever oscillation in AC modes) and amplitude (the amplitude of the oscillating cantilever in AC modes of operation).
The AFM scan may also be used to tell when the probe is interacting with different forces of adhesion (friction) at different domains on the surface. This interaction force is a consequence of the interaction between the molecules on the probe and on the surface. When there is a specific interaction, the force value is typically higher than for non-specific interactions, although this may not be universally true (since some non-specific interactions can be very strong). Therefore, it may be useful to include both known positive and negative control domains in the scan area to help distinguish between specific and non-specific force interactions. The target sample may affect the deposition material 56 that can be read by this scanning technique. A still further embodiment may directly measure the interaction forces between a molecular probe coupled to the AFM tip and the surface. The direct measurement of molecular unbonding forces has been well described in the art in addition to measuring changes in the elasticity.
In the screening methods described above, once it has been established that a molecular binding event has occurred, changes in the degree of binding upon introduction of additional sample molecules may also be analyzed. The potential for a third molecular species to enhance or inhibit a defined molecular interaction is of utility in locating new drugs and other important effectors of defined molecular interactions.
In the above examples an AFM is used for illustration purposes. The type of deposition instrumentation incorporated into the present invention is not limited to AFM's, or other types of SPM's. In one alternative embodiment, a dedicated deposition instrument may be used which may provide for extremely accurate control of the deposition probe. In this alternative embodiment, a DC stepper motor and a piezoelectric motion control device may be incorporated for sample and probe control. In still further embodiments, a force feedback system may be included to minimize the force exerted between the deposition tool and the surface.
One advantage to the present invention is the elimination of the labeling step required in other array 66 techniques. Radioactive and fluorescent labeling may be cost prohibitive and complex. The present invention eliminates the need for the labeling of molecular deposition domains 64 in an array 66 .
Another advantage to the present invention is the creation of molecular domains in an array 66 wherein each domain has a deposition area of less than one micron. Since the size of each domain is extremely small, a large number of domains may be placed in a small area, requiring less materials, a smaller medium sample for exposure, and the ability to perform a quicker scan.
Another advantage to the present invention array 66 is the ability to quickly scan for multiple molecular events in a reasonably short period of time.
III. ALTERNATIVE DEPOSITION EXAMPLES
The following are a few of the variations in the deposition method and array 66 apparatus that may be used within the scope of the present invention. These examples are given to show the scope and versatility of the present invention and are not intended to limit the invention to only those examples given herein. In each of these examples, the deposition material 56 may be deposited on the deposition device 40 and then to the surface utilizing the method described above, however the surface may be coated with other materials that will react in some way with the deposition material 56 , to bind the latter to the surface in the deposition domain 64 .
A. Surface Modification
One alternative embodiment for the covalent tethering of biomaterials to a surface for use in the present invention may be to use a chemically reactive surface. Such surfaces include, but are not limited to, surfaces with terminal succinimide groups, aldehyde groups, carboxyl groups, vinyl groups, and photoactivatable aryl azide groups. Other surfaces are known to those reasonably skilled in the art. Biomaterials may include primary amines and a catalyst such as the carbodiimide EDAC (1-ethyl-3-[3-dimethylaminopropyl]carbodiimide). Furthermore, the spontaneous coupling of succinimide, or in the alternative, aldehyde surface groups, to primary amines at a physiological pH may be incorporated for attaching molecules to the surface. In still another embodiment, photoactivatable surfaces, such as those containing aryl azides, may be utilized. These photoactivatable surfaces form highly reactive nitrenes that react promiscuously with a variety of chemical groups upon ultraviolet activation. Placing the deposition sample on the surface and then activating the material can create deposition domains 64 in spots or patterns, limited only by the light source activated.
Another embodiment for the tenacious and controlled binding of biomaterials to surfaces is to exploit the strong interactions between various biochemical moieties. For example, histidine binds tightly to nickel. Therefore, both nucleic acid and protein biomaterials may be modified using recombinant methods to produce runs of histidine, usually 6 to 10 amino acids long. This His-rich domain then allows these molecules to bind tightly to nickel coated surfaces. Alternatively, sulfhydryl groups can be introduced into protein and nucleic acid biomaterials, or preexist there, and can be used to bind the biomaterials to gold surfaces by virtue of extremely strong gold-sulfur interaction. It is well documented that gold binds to sulfur with a binding force comparable to that of a covalent bond. Therefore, gold-sulfur interactions have been widely exploited to tether molecules to surfaces. Jones, V. W., J. R. Kenseth, M. D. Porter, C. L. Mosher, and E. Henderson, Microminiaturized Immunoassays Using Atomic Force Microscopy and Compositionally Patterned Antigen Arrays 66 , Anal Chem. 1998, p. 1233-41.
B. Aptes
In this alternative embodiment, the surface may be treated with APTES (aminopropyl triethoxy silane). The APTES placed on the surface may present positively charged amino groups that can bind tightly to a negative charge. Materials such as DNA and RNA containing negatively charged groups may therefore bond to the surface after the APTES treatment. The details of the adsorption mechanism involved in this spontaneous attachment are not well defined. Therefore, in alternative embodiments, it may be advantageous to deposit biomaterials onto surfaces that can be covalently or otherwise tenaciously coupled to the target sample. DNA and RNA bind through interaction between their negative net charge and the net positive charge of the APTES surface.
C. Photochemical Sample Deposition
In this alternative embodiment, glass surfaces may be modified sequentially by two compounds, aminopropyltriethoxysilane (APTES) and N-5-azido-2-nitrobenzoyloxysuccinimide (ANB-NOS). The glass may first be treated with APTES to generate a surface with protruding amino groups (NH 2 ). These groups may be then reacted with the succinimide moiety of ANB-NOS in the dark. These steps produce a surface with protruding nitrobenzene groups. The photosensitive surface may be then reacted with the first deposition material 56 in the dark, then a focused light source, like a laser, may be used to illuminate a portion of the surface. These acts result in localized covalent binding of the first deposition material 56 to the surface. The deposition material 56 not bonded to the surface may then be washed away and second deposition material 56 added by repeating the process. Reiteration of this process results in the creation of a biomolecular array 66 with address dimensions in the 1 micron size range. A limitation of this deposition method is that the sample size is dependent on the size of the illuminating light field.
A variation of the above embodiment may be to utilize the deposition device 40 and humidity ramping deposition technique described to place various molecular species at defined locations in the dark. After construction of the desired array 66 , the entire surface is exposed to light, thereby cross linking the molecular species at discrete spatial domains. This process may overcome the spatial limitation imposed by use of a far field laser or other type of light beam.
D. Photocoupling
In this embodiment a near field scanning optical microscope (NSOM) may be used to supply the light energy necessary to accomplish photocoupling of the sample molecule to a surface at a defined spatial address. The NSOM may overcome the diffraction limit which constrains the address size created by far field photocoupling as described in Example 2. The photoactive surface is prepared as described in Example II. The first molecule to be coupled is added to the surface and subjected to a nearfield evanescent wave emanating from the aperture of the NSOM. The evanescent wave energy may then activate the photosensitive surface and result in coupling of the sample molecules to a spatial address in the 10 to 100 nm size range. The first sample molecule is washed away and the process repeated with a second sample molecule. Reiteration of this process may result in the production of an array 66 of sample molecules coupled at spatial addresses with submicron dimensions.
An alternative approach may be to utilize both the sample manipulation and near field light delivery capabilities of the NSOM. In this approach, the NSOM probe may be first loaded with a molecular species as described in Example I. Then the same probe is used to provide the light energy to couple the molecule to the surface. The probe may then be washed and reused to create a spatial array 66 of molecular species covalently coupled to defined domains.
One advantage of coupling the deposition material 56 to the surface may be that the molecule may remain attached at a defined spatial domain even under stringent wash and manipulation conditions. Moreover, by coupling the molecule, the orientation of the molecules on the surface may be controlled by the careful selection of a tethering method.
Yet another advantage to coupling the molecule is that by controlling the coupling chemistry, the minimization of the chances of surface induced molecular denaturation may be achieved. Coupling the molecules to the surface may be especially advantageous when depositing biomolecules.
The information and examples described herein are for illustrative purposes and are not meant to exclude any derivations or alternative methods that are within the conceptual context of the invention. It is contemplated that various deviations can be made to this embodiment without deviating from the scope of the present invention. Accordingly, it is intended that the scope of the present invention be dictated by the appended claims rather than by the foregoing description of this embodiment.
All publications cited in this application are incorporated by reference in their entirety for all purposes. | The invention is a method for the formation and analysis of novel miniature deposition domains. These deposition domains are placed on a surface to form a molecular array. The molecular array is scanned with an AFM to analyze molecular recognition events and the effect of introduced agents on defined molecular interactions. This approach can be carried out in a high throughput format, allowing rapid screening of thousands of molecular species in a solid state array. The procedures described here have the added benefit of allowing the measurement of changes in molecular binding events resulting from changes in the analysis environment or introduction of additional effector molecules to the assay system. The processes described herein are extremely useful in the search for compounds such as new drugs for treatment of undesirable physiological conditions. The method and apparatus of the present invention does not require the labeling of the deposition material or the target sample and may also be used to deposit large size molecules without harming the same. | 8 |
PRIORITY CLAIM
This nonprovisional application for patent claims priority of copending provisional application No. 60/244,873 filed Nov. 2, 2000.
BACKGROUND OF THE INVENTION
For safety reasons, it has been desirable to fasten truck wheel lug nuts with power tools (e.g., pneumatic drivers) that can deliver higher torques than have been obtainable by hand. As a result of this need for power assistance in tightening, a power driver is required any time a tire needs to be removed or the tightness of a nut needs to be checked or adjusted. This means that such work must be done in a service center, or, in the event of a roadside emergency, by either a roadside service vehicle or an on-board power driver if available. However, roadside service is expensive and time-consuming, and sufficiently powerful on-board equipment is expensive. A need exists for a lower cost alternative.
The lower cost alternatives are often manual tools. However, the use of manual tools on truck wheels is complicated by the fact that most truck wheels except those on the front end have lug nuts that are recessed as much as a foot from the outer edge of the tire. If a conventional wrench or breaker bar is used with an extension enabling access to these lugs, not only does the user have to support the weight of the wrench, he also has to balance his rotational force to keep from twisting the tool off the lug nut. The present invention anchors the tool and balances the forces so that only the modest weight of the tool need be supported manually.
SUMMARY OF THE INVENTION
The present invention is a tool for tightening or loosening a fastener, the tool being anchored against reactive force to a nearby fastener or stud, and utilizing a screw to pull or push a wrench handle against the anchor. The screw increases the hand torque applied to it to levels comparable to a power driver. Further, the tool is shaped to permit its use in the tight space found in the annular recess surrounding the hubs of most truck wheels. Principal objects of the invention are to provide: a) a hand tool capable of generating the very high torques needed to adjust truck wheel lug nuts with relatively low cost, weight, and space requirements; b) a tool that can be used on a variety of lug nut configurations including both recessed nuts (such as are typically found on rear axle wheels of tractor-trailer trucks) as well as easily-accessible nuts (such as those usually found on the front wheels of truck tractors); c) a tool designed so that the active and reactive forces are collinear and the moments coaxial so that the user does not have to resist applied forces during use of the tool to keep it in place; and d) a tool designed to keep internal stresses that would reduce efficiency due to friction to a low level.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of the tool contemplated by the present invention.
FIG. 2 is a perspective view of the wrench portion of the first embodiment.
FIG. 3 is a perspective view of the anchor portion of the first embodiment.
FIG. 4 is a perspective view of the first embodiment about to be applied to a work piece and an anchor piece on a typical truck wheel.
FIG. 5 is a view of the first embodiment from the viewpoint of a user when applied to a work piece and an anchor piece before the work piece is loosened.
FIG. 6 is a view of the first embodiment from the viewpoint of a user when applied to a work piece and an anchor piece after the work piece is loosened.
FIG. 7 is a perspective view of the first embodiment with an added torque indicator assembly.
FIG. 8 is a cutaway perspective view of the first embodiment with an added torque indicator assembly.
FIG. 9 is a close-up cutaway perspective view of the upper portion of the torque indicator assembly.
FIG. 10 is a perspective view from the left showing a simple configuration for engaging the two parts of the torque indicator assembly.
FIG. 11 is a perspective view of a second (preferred) embodiment of the tool contemplated by the present invention.
FIG. 12 is a perspective view of the wrench portion of the second embodiment.
FIG. 13 is a perspective view of the anchor portion of the second embodiment.
FIG. 14 is a perspective view of the second embodiment about to be applied to a work piece and an anchor piece on a typical truck wheel.
DETAILED DESCRIPTION OF THE INVENTION
Referring again to the drawings, in which like details are referenced by like numerals, a detailed description of the invention is given below.
FIG. 1 is a perspective view of the first embodiment of the tool contemplated by the present invention. It is an extended socket wrench, the handle of which is pulled by the action of a screw against a similarly extended and coaxial anchoring device. It comprises a wrench portion 1 having a wrench arm 2 , said wrench portion cooperating slidably and coaxially with an anchor portion 3 having an anchor arm 4 . The wrench arm 2 and the anchor arm 4 are gripped and moved relative to one another by an actuator assembly 6 comprising talons 5 a and 5 b , respectively, riding on a screw 7 that is threaded its entire length from point X to point Y. The distance between the talons is changed by rotating screw handle 8 in either direction. As oriented in FIG. 1 with threads being right handed, when the handle is rotated clockwise (toward the reader) the screw 7 pulls talon 5 b towards talon 5 a , thereby rotating wrench portion 1 counterclockwise within anchor portion 3 . The anchor portion 3 cannot rotate clockwise in reaction to this pull because it is held in place by anchor socket 9 , and so wrench socket 10 must turn counterclockwise. A small force on handle 8 is multiplied by the leverage of the arms 2 and 4 and the incline of the threads of screw 7 into a large torque at wrench socket 10 . The entire actuator assembly 6 is removable from the rest of the tool. In this embodiment, the arms 2 and 4 are hollow and the talons 5 a and 5 b grip them by means of round teeth (not shown) inserted into the arms. The depicted means of attaching the actuator assembly 6 to the arms 2 and 4 is not intended to exclude other equally strong attachment means, such as, for example, replacing the talon teeth with drill holes capable of being slipped over the ends of the arms.
The arms 2 and 4 extend an equal distance from the common axis of portions 1 and 3 . This ensures that the radial components of the forces on the arms (away from the axis of the tool) which would tend to detach the talons from the arms, are negligible. Further, the arms are bent as shown so that they interfere minimally when the talons are drawn close together by the screw. The bends in the arms also cause the plane of motion of the screw and the talons to be always normal to the common axis of portions 1 and 3 , thereby ensuring that forces collinear with the tool axis (thrust forces) which would tend to disengage the tool from the work piece and/or anchor piece, are minimal. If the forces on the tool components were to be diagrammed with vectors, the diagram would show net zero resultants and moments at all points except for the weight of the tool itself.
FIG. 2 is a perspective view of the wrench portion 1 of the first embodiment. It comprises a hollow shaft 20 to which is welded a wrench arm 2 at one end and a square socket drive 21 at the other. Wrench arm 2 is angled downward and rearward slightly at 22 , then upward and forward slightly at 23 , to better cooperate with the anchor arm depicted in the following figure. A conventional wrench socket (not shown) is affixed to the drive 21 to grip a lug nut on a truck wheel (not shown).
FIG. 3 is a perspective view of the anchor portion 3 of the first embodiment. It comprises a hollow tube 30 of an inside diameter greater than the outer diameter of hollow shaft 20 in FIG. 2 . Anchor arm 4 is welded to the upper end 31 of tube 30 . Arm 4 is angled upward and forward slightly at 24 , then downward and rearward slightly at 25 , to better cooperate with the wrench arm depicted in the preceding figure, i.e., so that the ends of both arms 2 and 4 always lie in the same plane, a plane perpendicular to the axes of shaft 20 and tube 30 , and so that the two arm ends can meet each other closely regardless of which way they are rotated. The depicted configuration of bends is not meant to preclude more rounded or more sharply bent arm shapes that would accomplish the same purpose.
To the lower end 32 of the tube 30 is fixedly attached a slotted guide 33 . The purpose of the guide 33 is to provide an adjustable anchor point for the tool on an adjacent lug nut. The distance between lug nuts on truck wheels varies due to the size and type of hub and the number of lug nuts per wheel, so the anchor point is comprised of a lug nut socket (not shown) on the square end 39 of a movable boss 35 that rides in the slot 38 of the guide 33 . The guide 33 is curved in a plane normal to the axis of tube 30 , the curvature having a radius R matching that of the typical lug nut array (not shown) on a truck wheel (not shown). This is helpful in the event the lug nuts are recessed into a narrow annular space around the hub of the wheel, as they often are; the width of the guide 33 and its attached parts is narrow enough to fit into the annular space containing the lug nuts. A bolt 34 is screwed into a square boss 35 through washer 36 , guide 33 and washer 37 without compressing the washers against the guide, so that the boss 35 can ride slidably along the guide 33 and rotate freely on an axis parallel to the axis of tube 30 . Boss 35 has a square end 39 identical to socket drive 21 of FIG. 2, so that identical and interchangeable sockets can be used on both the anchor piece and the work piece. The guide 33 and the washers 36 and 37 are wide in a direction normal to the axis of tube 30 so that when the boss 35 is pushed sideways by reactive torque during operation of the tool, the axis of boss 35 is kept parallel to the tool axis, reducing any tendency of the tool to twist loose from either the work piece or the anchor piece during use. The square end of boss 35 accommodates a conventional wrench socket (not shown) identical to that applied to the wrench shaft 20 of FIG. 2 which grips the anchor piece, typically another lug nut (not shown) on the same truck wheel.
FIG. 4 is a perspective view of the wrench portion 1 and the anchor portion 3 of the first embodiment assembled together coaxially and ready for application to a work piece 40 and an anchor piece 41 on a typical truck wheel 42 . Assembly is accomplished by sliding the square drive end of portion 1 into the upper end 31 of portion 3 until the wrench arm 2 comes in contact with upper end 31 . When applied to a wheel, the direction of anchor arm 4 will be toward whichever lug nut or stud is to be used as the anchor piece 41 for the tool. The orientation of wrench arm 2 about the tool axis may be any one of N directions for an N-sided socket applied to a work piece consisting of an N-sided lug nut. (N is typically six.) Out of these N directions, the user must choose the direction that will put the ends of the arms as far apart as they can be yet still be gripped by talons 5 a and 5 b on actuator assembly 6 (FIG. 1 ). Screw 7 of FIG. 1 should be long enough to span the ends of the arms 2 and 4 when the initial angle Ai between them, in their plane of revolution, is as large as about 110 degrees.
FIG. 5 is a view of the first embodiment from the viewpoint of a user when applied to a work piece (hidden under socket 10 ) and an anchor piece (hidden under socket 9 ) on truck wheel 42 before the work piece is loosened. Actuator assembly 6 may be put in place by rotating talon 5 b around the threads of screw 7 (or rotating screw 7 within talon 5 b ) until the distance between the talons is such that the talon teeth (not shown) can be inserted into the ends of arms 2 and 4 . Note the position of mark M on the side of wrench socket 10 , and the initial angle Ai between arms 2 and 4 .
FIG. 6 is a view of the first embodiment from the viewpoint of a user when applied to the same work piece and anchor piece after the work piece is loosened. Assuming right-handedness on all threads, handle 8 on actuator assembly 6 has been rotated in direction C (into the drawing) a number of times, drawing talon 5 b closer to talon 5 a and reducing angle Ai in FIG. 5 between arms 2 and 4 to angle Af This has caused shaft 20 to rotate counterclockwise within tube 30 a small amount, in turn forcing wrench socket 10 to rotate in a counterclockwise direction as well. This is clear from the fact that mark M on socket 50 in this figure has been displaced to the left of its position in FIG. 5 . Only a few degrees of motion should be necessary in most cases to loosen a work piece to a degree sufficient to enable complete removal by hand or conventional lug wrench after the talons 5 have been drawn fully together. In the event further loosening is required, it is necessary for the user to remove the actuator assembly 6 (to the right in this figure) from the arms 2 and 4 , re-orient the wrench portion 1 one “flat” clockwise on the work piece, wind talon 5 b away from talon 5 a on screw 7 , reapply the actuator assembly to the arms, and turn the handle in direction C again.
FIG. 7 is a perspective view of the first embodiment completely assembled as in FIG. 6, but with an added torque indicator assembly 74 comprising a rod 70 , a pointer 71 , a pivot 72 and a scale 73 attached to the shaft 20 and arm 2 of wrench portion 1 .
FIG. 8 is a cutaway perspective view of the first embodiment with the added mechanical torque indicator of FIG. 7 . The cutaway is necessary to show that the rod 70 extends all the way to the bottom end 78 of hollow shaft 20 . The lower end 75 of rod 70 is rigidly attached to the inside of the bottom end 78 of hollow shaft 20 . The upper end 76 of rod 70 curves over the top edge 77 of shaft 20 and flexibly engages pointer 71 , as is more clearly shown in FIGS. 9 and 10. Pivot 72 and scale 73 are fixedly attached to arm 2 .
FIG. 9 is a close-up cutaway perspective view of the upper portion of the mechanical torque indicator of FIG. 7, more clearly showing how pin 80 through pointer 71 rests slidably on pivot 72 . When wrench arm 2 is pulled toward the viewer in an attempt to loosen a lug nut engaged by drive 21 on the bottom of shaft 20 (not visible), the arm 2 will apply a counterclockwise torque on shaft 20 as indicated by arrow T. This torque will cause the top edge 77 of shaft 20 , as well as arm 2 , pivot 72 , and scale 73 , to be displaced in a counterclockwise direction relative to the bottom of the shaft (not shown) because of the elasticity of the material in the shaft. The curved upper end 76 of the indicator rod 70 , however, because it is rigidly attached to the bottom of the shaft, tends not to move with the upper end of shaft 20 and attached parts. The upper end 76 of rod 70 tends therefore to prevent the inner end 82 of pointer 71 from moving counterclockwise. Because the pivot 72 is also moving counterclockwise with arm 2 , it tends to rotate pointer 71 counterclockwise about pivot 72 , causing the tip 81 of the pointer 71 to move in a counterclockwise direction. Because pivot 72 is much closer to the upper edge 77 of the shaft 20 than the center 83 of the pointer 71 , The counterclockwise motion of pointer tip 81 is magnified relative to the counterclockwise rotation of arm 2 and scale 73 , so that tip 81 will move visibly over the scale 73 toward the viewer in this drawing. All of these displacements will be proportional to the applied torque, and as long as the elastic limit of the shaft material is not exceeded, they will also be reproducible. Therefore, indicia 84 may be placed on the scale 73 in units of torque to indicate replicable torque readings. Such readings may be of use in preventing the hazard of over- or under-tightening fasteners.
FIG. 10 is a close-up perspective view of the mechanical torque indicator from the left showing a simple means of flexibly engaging inner end 82 of pointer 71 with upper end 76 of rod 70 . A slot 90 formed into end 76 fits slidably over the upper comer 91 of inner end 82 so that rod 70 can push end 82 from side to side as torque in either direction is applied to the tool. This motion in turn causes a magnified and opposite side to side motion in the opposite end 81 of pointer 71 .
FIG. 11 is a perspective view of a second embodiment of the tool contemplated by the present invention. In the following figures, parts of the second embodiment corresponding to parts of the first embodiment are indicated by a prime (′) after the numeral. The second embodiment differs from the first in that: a) arm 2 of the preceding figures is replaced by driven gear 100 which is toothed around its entire periphery and is rigidly attached to the upper edge 77 of shaft 20 (now 77 ′ and 20 ′, respectively); b) arm 4 is shortened and comprises a worm gear bearing 101 . Bearing 101 comprises journals 102 a and 102 b , which hold a worm gear 103 which is turned by, and is fixedly engaged to, a handle 104 . The worm gear 103 , handle 104 , and bearing 101 and journals 102 replace the screw 7 , handle 8 and talons 5 shown in FIG. 1 . If The worm gear 103 has right-handed threads, it will engage the teeth of driven gear 100 such that when handle 104 is turned in direction D, the driven gear will turn in direction E, rotating shaft 20 ′, socket 10 ′, and a work piece (not shown) in the same direction. By suitably sizing the gears, arms and handle, sufficiently high mechanical advantage can be achieved to loosen the tightest fasteners with moderate manual pressure.
FIG. 12 is a perspective view of the wrench portion 1 ′ of the second embodiment, comprising shaft 20 ′, square drive 21 ′, and driven gear 100 .
FIG. 13 is a perspective view of the anchor portion 3 ′ of the second embodiment, comprising tube 30 ′, a shortened anchor arm 4 ′, and worm gear bearing 101 welded to arm 4 ′. The remaining parts of the anchor portion of the second embodiment are the same as those of the first embodiment.
FIG. 14 is a perspective view of the wrench portion 1 ′ and the anchor portion 3 ′ of the second embodiment assembled together coaxially and ready for application to a work piece 40 and an anchor piece 41 on a typical truck wheel. Assembly and positioning are accomplished first by sliding the square drive end of the wrench portion 1 ′ into the upper end 31 ′ of anchor portion 3 ′, and attaching wrench socket 10 ′ and anchor socket 9 ′ to the square drive (hidden) and anchor boss (hidden) respectively; second, by placing the anchor socket 9 ′ over anchor piece 41 ′ on a wheel next to whichever work piece 40 ′ it is desired to loosen; and third, by placing the wrench socket 10 ′ over the selected work piece 40 ′. It may be necessary to turn the driven gear 100 by hand prior to meshing the driven gear 100 and the worm gear 103 , or by meshing these gears and then turning handle 104 in either direction, to cause the wrench socket 10 ′ to fit over the work piece 40 ′. The work piece 40 ′ can then be loosened or removed completely, without removing the tool from the wheel, by turning handle 104 as many revolutions as required.
Although not specifically illustrated, the torque indicator portion of the first embodiment may also be incorporated readily into the second embodiment by affixing the pivot 72 and the scale 73 of FIG. 7 to the upper surface of the driven gear 100 of FIG. 11, the rest of the assembly being identical to that shown in FIG. 8 . Further, it is noted that similar mechanical torque indicating devices may be attached alternatively to anchor portion 3 . Still further it is noted that in either of the embodiments, an electronic strain gauge may be attached to any one of various stressed parts of this tool, instead of mechanical indicator parts, such that an analog or digital readout of torque could be displayed at a convenient spot on the tool. For example, a strain bridge could be attached to the inner.wall of wrench shaft 20 or 20 ′, energized by a small battery and readable by a potentiometer installed in the shaft and displayed on an LCD mounted on top of the shaft.
In light of the drawing descriptions, the differences between these two embodiments can be summarized by saying that the first embodiment may be less expensive than the second to fabricate, because it does not comprise gears and does not require the small manufacturing and assembly tolerances necessary for smooth and efficient meshing of the gears. The advantage of the second embodiment is one of convenience, in that the loosening process can be extended to the point of complete removal of the fastener, if desired, without repositioning parts of the tool.
This invention contemplates a third embodiment, not illustrated, in which a pipe wrench is employed in place of wrench arm 2 in the first embodiment. The jaws of the pipe wrench are placed around that section of shaft 20 protruding above tube 30 so that they grip the shaft when the handle of the pipe wrench is pulled in the fastener-loosening direction. A screw-operated actuator assembly capable of gripping the handle of the pipe wrench and the end of anchor arm 4 similar to assembly 6 shown in the illustrations of the first embodiment is used to pull the handle of the pipe wrench toward anchor arm 4 . A common c-clamp or bar clamp with its ends adapted to hold securely the handle of the pipe wrench and the end of anchor arm 4 serves the purpose of an actuator for this third embodiment of the tool. The advantage to this embodiment over the first two might be cost if a suitable pipe wrench and clamp are available. | A tool for adjusting extremely tight lug nuts, such as often found on tractor-trailer trucks, consists of a socket wrench pulled by a screw and anchored against another lug nut coaxial to the one being adjusted. A hand crank turns the screw, which in turn pulls the handle of the socket wrench toward the anchor yielding very high torque multiplication. The tool is elongated and shaped to permit its use in the tight space found in the annular recess surrounding the hubs of most truck wheels. | 1 |
This application is a continuation of U.S. application Ser. No. 07/693,540, filed Apr. 30, 1991, now abandoned.
FIELD OF THE INVENTION
This invention relates to a material useful for improving living environment, and more particularly to a material useful for deodorization for animal breeding or keeping and a process for producing the same.
BACKGROUND OF THE INVENTION
Animal breeding or keeping is accompanied with an offensive smell mainly comprising ammonia, triethylamine, and sulfides. Deodorization in animal breeding or keeping has been effected with adsorbents, such as activated carbon, zeolite, bentonire, and impregnated pulp, and deodorant sprays. In keeping, e.g., cats indoors, since excrements of cats give off an awful smell, zeolite, bentonire, siliceous sand, etc. are used as toilet sand, which is disposed after each use. However, if these non-combustible materials are disposed together with combustible garbage, such would be a cause of obstruction of public facilities of garbage incineration, giving rise to a serious social problem.
Impregnated pulp, which has recently been extending its use because of its combustibility, has poor deodorizing effects. Moreover, since it is easily electrified, it adheres to the paws, making the floor dirty. The same disadvantage also applies to activated carbon.
Deodorant sprays only show a slight masking effect, furnishing no fundamental means of deodorization.
Thus, the problem of smell associated with animal breeding or keeping has not yet come to a satisfactory solution. Besides the problem of domestic animals, in cities of growing population, there is an increasing demand for a solution to the problem of smell of laboratory animals from the standpoint of environmental hygiene in the neighborhood.
SUMMARY OF THE INVENTION
In the light of the above-described situation, an object of the present invention is to provide a material capable of effectively removing bad odors of outputs and excrements of animals and a process for producing such a material.
The inventors have conducted extensive investigations and, as a result, it has now been found that the above object of the present invention is accomplished by a formed article of a pulp and/or polyolefin base material, said formed article having a cation exchange group.
DETAILED DESCRIPTION OF THE INVENTION
The base material which can be used in the present invention comprises pulp and/or a polyolefin, such as paper pulp, regenerated paper, polyethylene, and polypropylene. The base material to be used can be appropriately selected from among them according to the end use. The base material preferably has a fibrous form for assuring a wider surface area, which leads to an increased rate of adsorption of harmful substances, and ease of forming into any desired shape. The fibers preferably have a diameter of from 1 to 50 μm. With the fiber diameter being within this range, graft polymerization takes place uniformly over the cross-section of fibers.
A formed article comprising the base material has an aggregate form, such as mat, non-woven fabric, or a mass of spheres or flakes. For use as a toilet for cats, spherical or flaky formed articles are preferred for making it easy for cats to dig in as their habit. The spherical or flaky formed articles preferably have a size of from 2 to 20 mm. If they have too a large size, it is likely that family animals like cats play with them and bring them out of the toilet.
A reactive monomer is graft-polymerized to the formed article to introduce a cation exchange group. The reactive monomer which can be used in the present invention include those having a cation exchange group or a group capable of being converted to a cation exchange group. Examples of such reactive monomers are glycidyl methacrylate, glycidyl acrylate, styrene, and sodium styrenesulfonate. Examples of suitable cation exchange groups include a carboxyl group, a sulfo group, and a phospho group. The cation exchange group is preferably introduced into the formed article in an amount of from 0.5 to 8 mmol/g.
Graft polymerization of the reactive monomer to the formed article can be carried out, for example, by polymerization in the presence of an initiator, thermal polymerization, irradiation-induced polymerization using ionizing radiation, e.g., α-rays, β-rays, γ-rays, accelerated electron rays, X-rays, and ultraviolet rays. Polymerization induced by γ-rays or accelerated electron rays is suitable for practical use.
The amount of a reactive monomer polymerized on the formed article is expressed in terms of grafting rate (%) obtained from equation: ##EQU1##
In the present invention, a grafting rate preferably ranges from 10 to 150%. If the grafting rate is out of this range, performance properties characteristic of the base material tend to be impaired.
Modes of graft polymerization of a reactive monomer to a formed article are divided into liquid phase polymerization in which a formed article is directly reacted with a liquid reactive monomer and gaseous phase polymerization in which a formed article is brought into contact with vapor or gas of a reactive monomer. Either of these modes of polymerization can be chosen in the present invention according to the end use or purpose.
Substances giving off a bad smell of ammonia, triethylamine, etc. can be removed on neutralization reaction with a strongly acidic cation exchange group. That is, the deodorizing material according to the present invention achieves deodorization predominantly through chemical adsorption without being accompanied by desorption of the smell irrespective of environmental changes, whereas most of conventional inorganic adsorbents conduct deodorization through physical adsorption and are therefore liable to release once adsorbed substances depending on environmental changes. In addition, the deodorizing material of the present invention is easily regenerated by washing or a like means for reuse.
The present invention is now illustrated in greater detail with reference to the following Examples, but it should be understood that the present invention is not construed as being limited thereto. All the percents, parts, and ratios are by weight unless otherwise indicated.
EXAMPLE 1
Regenerated paper pulp flakes having an average diameter of 5 mm were soaked in the same volume of a glycidyl methacrylate solution for 10 minutes. After the excess liquid was removed, the impregnated flakes were placed in an irradiation chamber. After rendering the chamber oxygen-free, cobalt 60 γ-rays were irradiated on the flakes at an absorption dose of 1 Mrad to induce graft polymerization to obtain a graft polymer. The resulting polymer was washed with dimethylformamide and then immersed in a 10% propanol-water solution of sodium sulfite at 80° C. for 5 hours to conduct sulfonation. There was obtained a deodorizing material containing 2.5 mmol of a sulfo group per gram of the base material.
A hundred parts by weight of commercially available toilet sand for cats were mixed with 10 parts by weight of the resulting deodorizing material, and the mixed sand was placed in a room having a floor space of about 10 m 2 where a cat was allowed to excrete. After one day, a pungent smell of the cat's excrements was imperceptible 1 m apart from the toilet sand. At this time, the ammonia concentration in the atmosphere 1 cm apart from the surface of the toilet sand was 0.2 ppm as measured with a gas detector. After 2 weeks, the toilet slightly smelled at 1 m distance. At this time, the ammonia concentration at 1 cm distance from the toilet sand was 0.5 ppm as measured with a gas detector.
For comparison, the same test was carried out using toilet sand containing no deodorizing material of the invention. After 1 day, the cat's excrements irritatingly smelled all over the room, and the ammonia concentration 1 cm distant from the surface of the toilet sand was 2 ppm as measured with a gas detector. After three days, the smell was so irritant that one could not stay any more in that room with all the windows and doors shut. The toilet was moved to another place, but the awful smell still remained in the room event after one night had elapsed. So, 30 g of the above prepared deodorizing material packaged in a net was suspended in the center of the room. One day after the suspension, the room had no bad smell at all.
From these results, the deodorizing material of the present invention was proved to produce remarkable deodorizing effects when used either alone or in combination with conventional toilet sand.
EXAMPLE 2
Polypropylene fibers having a diameter of 20 μm were formed into spheres having an average diameter of 5 mm. Accelerated electron rays were irradiated on the spheres in a nitrogen atmosphere at a dose of 10 Mrad by means of an electron beam accelerator. The irradiated spheres were brought into contact with an oxygen-free acrylic acid solution for 2 hours to conduct graft polymerization, followed by washing with a large quantity of warm water. There was obtained a deodorizing material containing 5.6 mmol of a carboxyl group per gram of the base material.
Thirty grams of the resulting deodorizing material were put in a nest box of hamster. After one day, the ammonia concentration in the box was 0.2 ppm as measured with a gas detector. Even after one week, it was not more than 0.5 ppm.
For comparison, when the same test was conducted without using the deodorizing material of the present invention, the ammonia concentration after one day was 1.2 ppm, clearly demonstrating the adsorptive effects of the deodorizing material of the present invention.
While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be make therein without departing from the spirit and scope thereof. | A deodorizing material for breeding or keeping animals and a process for producing the same are described. The material comprises a formed article of a pulp and/or polyolefin base material, wherein said formed article has a cation exchange group. The material is produced by graft polymerization of a reactive monomer having a cation exchange group to a formed article of a pulp and/or polyolefin base material. The material efficiently adsorbs bad smells of animals' excretions through chemical bonding. | 1 |
This application is a division of application Ser. No. 07/764,745 filed Sep. 24, 1991, now allowed.
FIELD OF THE INVENTION
This invention is directed to N-allyl-N-dialkoxyethyl amide or amine monomers, their preparation, and their use as crosslinking agents in emulsion copolymers that can be thermoset without the release of formaldehyde. This invention is further directed to nonwoven fabrics bonded with those emulsion copolymers and a process for the preparation of those nonwoven fabrics.
BACKGROUND OF THE INVENTION
Emulsion polymers are widely used to bind nonwoven fibers into fabrics for use as facings or topsheets in diapers, bed pads, hospital gowns, and other such uses. The typical emulsion polymers for this use are prepared predominantly from ehtylene, vinyl acetate, vinyl chloride and acrylate esters in combination with styrene or acrylonitrile, and use N-methylolacrylamide as the cross-linking agent. Although N-methylolacrylamide is widely used in the industry and provides excellent wet and dry tensile strength to the nonwoven fabrics, it suffers from two major drawbacks. N-methylolacrylamide is an equilibrium composition of acrylamide with free formaldehyde. Formaldehyde is a suspected carcinogen. A latex that uses N-methylolacrylamide as a latent crosslinking monomer will contain quantities of free formaldehyde, and consequently the nonwoven substrates bound with emulsion polymers containing N-methylolacrylamide will contain detectable quantities of free formaldehyde. In addition, acrylamide derivatives, including N-methylol acrylamide, are capable of undergoing strongly exothermic homopolymerization reactions, which makes processing, transportation and storage of acrylamides difficult.
The N-allyl-N-dialkoxyethyl amide or amine monomer of the present invention is not in equilibrium with free formaldehyde, yet it provides latent crosslinking ability similar to the N-methylolacrylamide compounds. It also does not undergo strongly exothermic homopolymerization reactions.
U.S. Pat. No. 4,788,288, issued to Pinschmidt, Jr. et al., discloses N-olefinically substituted cyclic hemiamidals and hemiamide ketals, and N-olefinically substituted dialkyl acetals and ketals, which can be incorporated into free radical addition polymers to give formaldehyde-free compositions. U.S. Pat. No. 4,959,489 issued to Nordquist et al. discloses a process for making an N-substituted acrylamide containing dialkyl acetal groups. However, the starting materials for some of these compositions are expensive and there is still a need for inexpensive formaldehyde-free compositions for use in emulsion binders for nonwoven fabrics.
SUMMARY OF THE INVENTION
This invention provides formaldehyde-free monomers, emulsion copolymers formed with those monomers, and nonwoven fabrics bound by the emulsion copolymers. This invention also provides a process for the preparation of the monomer and a process for the preparation of the nonwoven fabric. The monomer is an N-allyl-N-dialkoxyethyl amine or amide, given the acronym NANDA, which can be copolymerized with one or more monoethylenically unsaturated comonomers to provide an emulsion binder for nonwoven fabrics. The fabrics bound with a binder formed from the NANDA monomer have comparable dry strength and solvent strength to fabrics formed with binder crosslinked with the N-methylolacrylamide, NMA.
DETAILED DESCRIPTION OF THE INVENTION
The N-allyl-N-dialkoxyethyl amide or amine monomers of the invention are represented by the formula: ##STR2## in which R 1 and R 2 are C 1 -C 3 alkyl; R 3 is hydrogen, C 1 -C 3 alkyl, or R 4 --C(O)--; and R 4 is C 1 -C 3 alkyl or C 6 -C 8 aryl. Preferably, R 1 and R 2 are independently methyl or ethyl and R 3 is CH 3 --C(O)--.
The monomer compounds of the invention are easily prepared through two routes utilizing readily available and inexpensive starting materials. In one route, an amino acetaldehyde acetal is reacted with allyl chloride under basic conditions to give an N-allyl-N-dialkoxyethyl amine, which is optionally further reacted with an acylating agent to give an N-allyl-N-dialkoxyethyl amide. Alternatively, a chloroacetaldehyde acetal is reacted under mildly basic conditions with an allyl amine to give an N-allyl-N-dialkoxyethyl amine, which is optionally further reacted with an acylating agent to give an N-allyl-N-dialkoxyethyl amide.
The acetals used as starting materials can be prepared by standard organic synthesis methods. For example, U.S. Pat. Nos. 4,642,389 and 4,642,390 issued to Neigel disclose methods of manufacture of acetals suitable for starting materials.
The reactions for the synthesis of the amine and amide monomers can be carried out neat or in any solvent suitable to the reactant compounds and product. If solvents are used, solvents suitable for the amine synthesis are polar solvents, preferably water or isopropanol, and solvents suitable for the amide synthesis are nonpolar solvents, preferably diethyl ether or toluene.
The resulting monomers are liquids stable at room temperature or at moderately elevated temperatures (<50° C.) without the need for the addition of inhibitors to prevent homopolymerization.
In another embodiment, the N-allyl-N-dialkoxyethyl amines or amides can be copolymerized with other monomers to form emulsion polymers suitable for use as binders, particularly binders for making nonwoven fabrics. Suitable comonomers for copolymerization with the NANDA monomers include vinyl acetate, acrylic acid, acrylamide, olefins (such as ethylene), vinyl halides (such as vinyl chloride), C 1 -C 8 alkyl acrylates or methacrylates, and mixtures of these comonomers.
The NANDA monomers are present in the copolymer in an amount from about 1% to about 10% by weight of the copolymer, and preferably from about 4% to about 6% by weight of the copolymer. The other copolymerizable monomers are present in the copolymer in an amount from about 90% to about 99% by weight of the copolymer, and preferably from about 94% to about 96% by weight of the copolymer.
Suitable monomer mixtures for copolymerization with the N-allyl-N-dialkoxyethyl amines or amides are a mixture of 50%-90% vinyl acetate and 50%-10% ethylene by weight of the comonomer mixture, mixtures of 50%-90% vinyl acetate and 50%-10% acrylate esters by weight of the comonomer mixture, or mixtures solely of acrylate and methacrylate esters.
The copolymer may also contain an hydroxyl-containing comonomer as a coreactant for the NANDA monomer. The coreactant monomer may be present in an amount up to about 10% by weight of the comonomer mixture. The preferred hydroxyl-containing reactive comonomers are hydroxyethyl acrylate or hydroxypropyl acrylate and the corresponding methacrylates.
The polymerization of the NANDA monomers with the above mentioned comonomers is effected by conventional batch, semi-batch or continuous emulsion polymerization techniques well known in the art. Generally, the comonomers are polymerized in an aqueous medium (under pressures not exceeding 100 atmospheres if ethylene is employed) in the presence of an initiator and at least one emulsifying agent.
The polymerization is initiated by an effective amount of a free-radical initiator such as hydrogen peroxide, ammonium persulfate, sodium persulfate, potassium persulfate, or tert-butyl hydroperoxide, in amounts of between 0.01% and 3% by weight, preferably 0.01% and 1% by weight based on the total amount of the emulsion. The free radical initiators can be used alone or in combination with suitable reducing agents, such as ferrous salts, sodium dithionite, sodium metabisulfite, sodium thiosulfate and ascorbic acid to form a resox initiator system employed in amounts of 0.01% to 3%, preferably 0.01% to 1% by weight of the total emulsion. The initiators can be charged in the aqueous emulsifier solution or be added during the polymerization in doses.
The polymerization is carried out at a pH of between 2 and 7, preferably between 3 and 5. In order to maintain the pH range, it may be useful to work in the presence of customary buffer systems, for example, in the presence of alkali metal acetates, alkali metal carbonates, or alkali metal phosphates. Polymerization regulators, like mercaptan, aldehydes, chloroform, ethylene chloride and trichloroethylene, can also be added when needed.
The emulsifying agents used in the polymerization can be any of those generally known and used in emulsion polymerizations. Suitable emulsifying agents are anionic, cationic or nonionic emulsifiers or surfactants, or mixtures of them. Examples of suitable anionic emulsifiers are alkyl sulfonates, alkylaryl sulfonates, alkyl sulfates, sulfates of hydroxyalkanols, alkyl and alkylaryl disulfonates, sulfonated fatty acids, sulfates and phosphates of polyethoxylated alkanols and alkylphenols, and esters of sulfosuccinic acid. Examples of suitable cationic emulsifiers are alkyl quaternary ammonium salts and alkyl quaternary phosphonium salts. Examples of suitable nonionic emulsifiers are the addition products of 5 to 50 moles of ethylene oxide adducted to straight-chain and branched-chain alkanols with 6 to 22 carbon atoms, or alkylphenols, or higher fatty acids, or higher fatty acid amides, or primary and secondary higher alkylamines, and block copolymers of propylene oxide with ethylene oxide. Combinations of these emulsifying agents may also be used, in which case it is advantageous to use a relatively hydrophobic emulsifying agent in combination with a relatively hydrophilic agent. The amount of emulsifying agent is generally from about 1% to 10%, preferably from about 2% to 8%, by weight of the monomers used in the polymerization.
Various protective colloids may also be used in place of, or in addition to, the emulsifiers described above. Suitable colloids include partially acetylated polyvinyl alcohol (e.g., up to 50% acetylated), casein, hydroxyethyl starch, carboxymethyl cellulose, gum arabic, and the like, as known in the art of synthetic emulsion polymer technology. In general, these colloids are used at levels of 0.5% to 4% by weight of the total emulsion.
The emulsifier or protective colloid used in the polymerization can be added in its entirety to the initial charge to the polymerization zone, or a portion of the emulsifier, for example, from 25% to 90%, can be added continuously or intermittently during polymerization. The particle size of the emulsion can be regulated by the quantity of nonionic or anionic emulsifying agent or protective colloid employed. To obtain smaller particle sizes, greater amounts of emulsifying agents are used. As a general rule, the greater the amount of the emulsifying agent employed, the smaller the average particle size.
The polymerization reaction is generally continued until the residual monomer content is below about 1% of total emulsion mass. The completed reaction product is then allowed to cool to about room temperature, while sealed from the atmosphere.
The emulsions are produced and used at relatively high solids contents, for example, between 35% and 70%, preferably not less than about 50%, although they may be diluted with water if desired.
When the emulsion polymers derived from the monomers of this invention are used as binders to prepare nonwoven fabrics, other additives conventionally employed in similar binders may be added to the emulsion. Examples of such additives are defoamers, pigments, catalysts, wetting agents, thickeners, and external plasticizers. The choice of additives and the amounts in which they are added are well known to those skilled in the art. These additives may be formulated into the emulsion binder if their stability in aqueous dispersion is high, or they may be added to the emulsion binder just before application if their stability in the emulsion is low.
Binders described above are suitably used to prepare nonwoven fabrics by a variety of methods known in the art. In another embodiment, this invention is directed to the nonwoven fabrics bonded with the emulsion polymers derived from the inventive monomers. In general, the nonwoven fabrics are formed from a loosely assembled web of fibers impregnated with the emulsion binder. Before the binder is applied to the web of fibers, it is mixed with a suitable catalyst to crosslink the emulsion binder to itself and to the fibers. After impregnation with the emulsion binder, the web of fibers is dried with heating, which serves to cure the binder. Suitable catalysts are known in the art, and can be, for example, hydrochloric acid, oxalic acid, citric acid, or salts such as ammonium chloride. The catalyst is generally present in an amount of about 0.5% to about 2% of the total polymer.
The starting fibrous web can be formed by any one of the conventional techniques, such as carding, garnetting, or air-laying, for depositing or arranging fibers in a web or mat. In general, the fibers extend in a plurality of diverse directions in general alignment with the major plane of the fabric, overlapping, intersecting and supporting one another to form an open, porous structure. Fibers that may be used in the starting web can be natural or synthetic fibers, such as natural and regenerated cellulose fibers (we define cellulose fibers to mean those that contain predominantly C 6 H 10 O 5 groupings), wool, cellulose acetate, polyamides, polyesters, acrylics, polyethylene, polyvinyl chloride, and polyurethanes, alone or in combination with one another.
The starting fibrous web preferably weighs from about 5 to about 65 grams per square yard and more preferably weighs from about 10 to about 40 grams per square yard. After formation, the starting fibrous web is subjected to one or more of the bonding operations used in the art to anchor the individual fibers together to form a self-sustaining web. The bonding operations widely used are overall impregnation, or imprinting the web with intermittent or continuous straight or wavy lines or areas of binder extending transversely or diagonally across the web, and if desired, also along the web.
The amount of binder, calculated on a dry basis, applied to the fibrous starting web ranges from about 10 to about 100 parts or more per 100 parts of the starting web, and preferably from about 20 to about 45 parts per 100 parts of the starting web.
After impregnation with binder, the web is dried, usually by passing it through an air oven or over sections of heated cans, and then cured, usually by passing it through a curing oven or over sections of hot cans. Ordinarily, convection air drying is effected at 65° to about 95° C. for 2-6 minutes, followed by curing at 145° to about 155° C. for 1-5 minutes. However, other time-temperature relationships can be employed, for example, shorter times at higher temperatures or longer times at lower temperatures, and these relationships are well known to one skilled in the art.
The following examples are given to illustrate the present invention, and are not to be construed to limit the scope and spirit of the invention.
EXAMPLES
Example 1
Preparation of N-allyl-N-dimethoxyethyl Acetamide
Aminoacetaldehyde dimethyl acetal was reacted with allyl chloride to give N-allyl-N-dimethoxyethyl amine, which was then acetylated with acetyl chloride to give N-allyl-N-dimethoxyethyl acetamide, according to the following reactions: ##STR3##
Aminoacetaldehyde dimethyl acetal (70.0 grams, 0.666 mole), allyl chloride (25.5 grams, 0.333 mole), and NaHCO 3 (42.0 grams, 2 moles), were added to 99% isopropanol (117.75 grams, approx. 115 ml) in a one liter pressure vessel, and heated approximately to 100° C. under 140 psi of pressure for six hours. The reaction mixture was cooled to room temperature and the contents filtered and washed with isopropanol under vacuum to remove the salt precipitate. The filtrate was concentrated on a rotary evaporator at 50° C. to remove the isopropanol and diluted with excess diethyl ether, 50-100 ml, to cause additional precipitation. The crystals were collected and the filtrate was again concentrated on a rotary evaporator at 50° C. to remove the ether and to give 43.5 grams of crude product. The crude product was distilled at reduced pressure and 16.8 grams of the product was isolated at 70°-72° C. The structure of the product, N-allyl-N-dimethoxyethyl amine, was confirmed by NMR.
N-allyl-N-dimethoxyethyl amine (16.0 grams, 0.11 mole) and triethylamine (11.1 grams) were added separately to the reaction flask with diethyl ether (100 ml, 70.7 grams), and cooled to about 5°-10° C. Acetyl chloride (8.7 grams, 0.11 mole) was added to the reaction flask over approximately 20 minutes while maintaining the temperature at less than 20° C. The reaction mixture was diluted with 150 ml of diethyl ether and held at room temperature for one hour. The reaction mixture was filtered to remove triethylamine hydrochloride. The solvent was removed by rotary evaporation to give 20.0 grams of liquid product, identified as N-allyl-N-dimethoxyethyl acetamide by NMR.
Example 2
Alternate Route: Preparation of N-allyl-N-dimethoxyethyl Acetamide
Chloroacetaldehyde dimethyl acetal was reacted with allyl amine to give N-allyl-N-dimethoxyethyl amine, which was then acetylated with acetyl chloride to give N-allyl-N-dimethoxyethyl acetamide according to the following reactions: ##STR4##
Allylamine (708 grams, 12.17 moles) and chloroacetaldehyde dimethylacetal (440 grams, 3.5 moles) were charged to a 2 liter stainless steel autoclave and heated with agitation to 130° C. for 6.5 hours at 40 psig pressure. The reaction was cooled and 25% aqueous sodium hydroxide (560 grams, 3.5 moles) was added. Analysis by gas chromatography indicated 99.4% of the starting chloroacetaldehyde dimethyl acetal had reacted with the allyl amine. Bis(dimethoxyethyl) allyl amine accounted for about 4% of the products formed. The sodium chloride precipitate was filtered out and the remaining reaction mixture was distilled at atmospheric pressure through a 12 inch Vigreaux column. A fraction (889 grams) distilled from 100° C. to 120° C. was isolated and analyzed by gas chromatography as 98.6% N-allyl-N-dimethoxyethyl amine in 30% aqueous solution.
N-allyl-N-dimethoxyethyl amine (30% aqueous, 48.3 grams, 0.10 mole) was added to a glass reaction vessel fitted with a mechanical agitator. The agitator was started and sodium hydroxide (4.44 grams, 0.11 mole) was dissolved in the aqueous amine. Toluene (50 grams) was added and the mixture cooled to 0° to 5° C. Acetyl chloride (8.24 grams, 0.105 mole) was added over 10 minutes while maintaining the temperature below 5° C. The reaction mixture was stirred for 30 minutes at 5° C., agitation was stopped, and the mixture allowed to phase separate. The aqueous layer was discarded. Toluene was removed from the organic layer by rotary evaporation and 14.8 grams (0.08 mole) of N-allyl-N-dimethoxyethyl acetamide was isolated as confirmed by NMR.
Examples 3-5
Preparation of Emulsion Copolymers
Example 3 is an emulsion copolymer prepared with vinyl acetate and N-methylolacrylamide, and represents the industry standard. Examples 4 and 5 are emulsion copolymers prepared with the amide form of the NANDA monomer of the instant invention. TABLE I shows the composition in grams of Examples 3, 4, and 5, in which Example 3 is copolymer A, Example 4 is copolymer B, and Example 5 is copolymer C.
A two-liter four-necked flask was equipped with a stainless steel stirrer, condenser, addition funnel, nitrogen inlet, thermometer, and hot water bath. Initial-charge 1 was charged to the flask and purged with nitrogen. Initial-charge 2 was added to the reactor and the contents were heated to 78°-80° C. Five minutes after polymerization initiation was observed, Slow-add 1 (the monomer pre-emulsion mixture) and Slow-add 2 were added uniformly to the reactor over a four hour period. When Slow-add 1 and Slow-add 2 were completely added, the polymerization mixture was held for 45 minutes at 78°-80° C. and then cooled to room temperature. The emulsion polymer was then discharged.
Examples 6-11
Preparation of Nonwoven Fibrous Webs
The three copolymer compositions of Examples 3, 4, and 5, were each used to impregnate nonwoven fibrous webs of an air-laid wood pulp and of rayon. The resulting six examples were composed as follows:
Example 6: Pulp fibers impregnated with copolymer A.
Example 7: Pulp fibers impregnated with copolymer B.
Example 8: Pulp fibers impregnated with copolymer C.
Example 9: Rayon fibers impregnated with copolymer A.
Example 10: Rayon fibers impregnated with copolymer B.
Example 11: Rayon fibers impregnated with copolymer C.
TABLE I______________________________________ Ex. Ex. Ex.Formula Material 3/A 4/B 5/C______________________________________Initial-Charge 1 Distilled Water 349.1 396 396 Calsoft* 20% 1.0 1.0 1.0 Triton X305 70%** 3.0 3.0 3.0 Sodium Acetate 0.6 0.6 0.6 Ammonium Persulfate 0.8 0.8 0.8Initial-Charge 2 Vinyl Acetate 50 50 -- Butyl Acrylate 5 5 -- Ethyl Acrylate -- -- 35 Methyl Methacrylate -- -- 20Slow-Add 1 Distilled H.sub.2 O 90 90 90 Calsoft* 20% 10 10 10 Triton X305** 70% 6 6 6 Vinyl Acetate 325 325 -- Butyl Acrylate 120 120 -- Ethyl Acrylate -- -- 332 Methyl Methacrylate -- -- 113 N-Methylol 31.3 -- -- Acrylamide 48% NANDA*** 95% -- 29.2 29.2 Hydroxypropyl -- 19.3 19.3 AcrylateSlow-Add 2 Distilled Water 40 40 40 Ammonium Persulfate 1.0 1.0 1.0______________________________________ *A surfactant sold by Pilot Chemical Company **A surfactant sold by Union Carbide ***Nallyl-N-dimethoxyethyl acetamide
The individual fibrous webs were immersed in a 15% solids emulsion bath of copolymer of A, B, or C, corresponding to the examples as defined above, for approximately one minute. After removal from the bath, the webs were passed through nip rolls to remove excess emulsion to give samples containing 10% binder for pulp and 25% binder for rayon based on the weight of the starting fiber. The webs were dried on a canvas covered drier, and then cured in a forced air oven for two minutes at a temperature of 300° F. The webs were cut into strips 5 inches (12.7 cm) in machine direction and 1 inch (2.54 cm) in cross machine direction and evaluated for percent absorption of the copolymer (% pick up in weight over the basis weight), and for peak load and percent elongation when dry, wet with water, and wet with methyl ethyl ketone (MEK). Peak load and percent elongation are measures of tensile strength as tested on an Instron tensile tester Model 1130 equipped with an environmental chamber at crosshead speed of 10 cm/min. The gauge length at the start of each test was 3 inches (7.62 cm). The results of the tests are shown in TABLE II.
TABLE II______________________________________Example 6 7 8 9 10 11______________________________________Basis Weight* 10.6 11.1 10.4 23.6 25.2 25.3% Pick Up 36.8 37.3 37.3 21.4 18.4 17.9Dry Peak Load (lbs.) 6.31 5.57 5.37 2.39 1.47 1.11Dry % Elong. 5.8 6.1 6.1 11.1 10.8 11.3Wet Peak Load 2.57 2.09 2.33 0.98 0.44 0.46Wet % Elong. 10.2 10.4 10.1 25.8 28.9 27.7MEK** Peak Load 1.61 1.78 2.17 0.61 0.19 0.21MEK % Elong. 4.6 6.1 5.4 4.8 3.9 3.6______________________________________ *in grams per square yard **methyl ethyl ketone Example 6 is pulp fiber impregnated with the industry standard emulsion polymer prepared with vinyl acetate and Nmethylolacrylamide. Example 7 is pulp fiber impregnated with an emulsion polymer prepared wit NANDA and vinyl acetate. Example 8 is pulp fiber impregnated with an emulsion polymer prepared wit NANDA and acrylates. Example 9 is rayon fiber impregnated with the industry standard emulsion polymer prepared with vinyl acetate and Nmethylolacrylamide. Example 10 is rayon fiber impregnated with an emulsion polymer prepared with NANDA and vinyl acetate. Example 11 is rayon fiber impregnated with an emulsion polymer prepared with NANDA and acrylates.
The data in Table II show that the fibrous webs impregnated with the emulsion polymer formed from the NANDA monomer, which contains no formaldehyde, performed comparably on pulp and acceptably on rayon to the webs impregnated with the industry standard emulsion polymers formed with N-methylolacrylamide (NMA), which contain formaldehyde. Specifically, the NANDA containing emulsion polymers showed 85-88% of dry strength, 81-91% of wet strength, and 110-134% of solvent strength compared to the NMA containing lattices when used on air-laid wood pulp substrate, and 46-62% of dry strength, 45-47% of wet strength, and 31-34% of solvent strength compared to the NMA containing lattices when used on rayon substrate.
Various modifications and improvements on the above described examples will be apparent to those skilled in the art without departing from the spirit or scope of this invention. | A formaldehyde-free latent crosslinking monomer represented by the formula ##STR1## in which R 1 and R 2 are C 1 -C 3 alkyl; R 3 is hydrogen, C 1 -C 3 alkyl, or R 4 --C(O)--; and R 4 is C 1 -C 3 alkyl or C 6 -C 8 aryl, contains an allyl group capable of undergoing addition copolymerization and a dialkoxy ethyl group capable of crosslinking under acidic conditions. The monomer can be copolymerized with comonomers to form emulsion polymers for use as formaldehyde-free binders in nonwoven textiles. Methods for the preparation of the monomer, the polymers, and the nonwoven fabrics are described. | 3 |
FIELD OF INVENTION
[0001] The present invention is directed to an aqueous composition containing high purity iron oxide pigments. The compositions involved are particularly useful for providing coloration and other properties to a large variety of pharmaceutical, food, pet food, cosmetics, personal care products and other systems where high purity, high quality products are necessary and where the customer desires a liquid product to incorporate into such customer's manufacturing processes.
BACKGROUND OF INVENTION
[0002] In General
[0003] Since at least the middle of the Nineteenth Century to the very present day, iron oxide has been used as the pigment of choice in an ever expanding and increasing variety of systems. Natural iron oxide, actually was mined and used in paints before the American Civil War and such paint use continues, on a very large scale, into the Twenty First Century Waxes, coatings, inks, paper and a growing number of other new products continue to depend on iron oxide to provide the bright colors which some people believe define the vividness of modernity and our present time
[0004] Most recently iron oxide (and chromium oxide) have been used in the pigmentation of cosmetic and pharmaceutical products. Metal oxide pigments have been used in the form of a powder in these businesses until very recently when customer preferences for a liquid formulation became known
[0005] Powdered metal oxide pigments are dusty, thereby giving rise to health hazards and making storage and handling difficult. Also, the powders are not free flowing and so cannot readily be conveyed through pipes, which become blocked by the powder. Further, the poor flowing properties of powders makes it hard to meter them using for example auger screws to ensure the correct proportion of pigment to base material
[0006] An increasing number of iron oxide customers have simultaneously been expressing a preference for relatively new high purity iron oxides. This iron oxide product is manufactured to meet more modem rigid standards of reduced trace elements; many of which elements either have been identified with health problems or are of a type not applicable to uses where food or skin contact is involved.
[0007] Prior Developments
[0008] Similar powder problems are known in other industries (e.g., in the concrete industry). Such problems have been solved to a substantial extent by granulating iron oxide products into large size granules 100 s of times larger than iron oxide pigment particles Granules have been difficult to optimize and are the subject of an ongoing investigation by many companies with much prior art reflecting the search for a process that is both effective in producing useful granules and is relatively inexpensive to implement.
[0009] Most cosmetic, pharmaceutical, and food customers however have resisted granules and have expressed a preference for a liquid iron oxide delivery system which would provide ease of use in the customer's manufacture. Many systems such as cosmetic and pharmaceutical making are largely liquid and pumpable/pourable raw materials in a water base would be very welcome.
[0010] U.S. Pat. No. 5,401,313 issued to Elementis Pigments, Inc., the assignee of this invention, describes a spray drying process wherein a granule is created with an added step of coating the iron oxide pigment particles with electric charges through use of a coating is utilized. The granules of iron oxide is presently useful in coloring concrete.
[0011] U.S. Pat. No. 5,853,476 also issued to Elementis Pigments, Inc., shows a compaction process relying in a preferred embodiment on Bepex MS compactors to make iron oxide granules. While very effective, the process is relatively expensive. The patent teaches the use of recycling of oversize and undersize material streams in a process that both creates enhanced color saves the cost of waste disposal. The final product is a solid granule.
OBJECT OF THE INVENTION
[0012] It is an object of the present invention to produce an aqueous dispersion of high solids content high purity iron oxide that is readily and very rapidly dispersible in a base medium, thereby eliminating dusting. It is a further important object to use in such dispersion from 5 to 80% high purity iron oxide.
[0013] It is a further object of the present invention to provide a process of manufacturing such dispersion and then selling such inventive products to customers as coloring ingredients in, for example, cosmetic, food, pet food, and pharmaceutical formulae
DETAILED DESCRIPTION OF INVENTION
[0014] According to the present invention, there is provided an aqueous dispersion of high purity iron oxide pigment preferably containing one or more preservatives
[0015] The aqueous composition of this invention is a composition where water comprises from about 20% to about 95% by weight of the total composition—when we use the word aqueous, we mean a liquid system based on water. The water preferably used is itself of high purity and clarity. Mineral water including Evian and Evian-type water can be used in high end dispersions targeted to the cosmetic industry particularly lipsticks, face creams, rouges and mascaras. Water obtained from artesian wells or other sources not affected by urban pollution is also preferred Preferred for most food and pharmaceutical uses however would be tap water preferably subjected to at least one secondary impurity treatment.
[0016] The present invention relates to a iron oxide suspension with high solids content and to a process for the preparation thereof The present invention uses as the starting material high purity iron oxide pigment prepared for example through the reaction of iron salts with an oxygen-containing gas in a reactor utilizing well known processes for manufacturing iron oxide, slurried in water with or without the use of a dispersing agent.
[0017] The key to high purity lies generally in special selection of raw materials used to make a purified iron starting solution to make the iron oxide. Raw materials include specifically selected steel and acid. Steel selected for purity includes steel free of organic contaminants and low in heavy metals, for example, stampings from steel cans used for food products. Acids are selected from, for example, sulfuric and hydrochloric acid, that has not been regenerated from heavy metals containing processes.
[0018] Representative manufacturing processes to make high purity iron oxide can vary. Generally the processes may be categorized into two types 1) precipitation, and 2) thermal decomposition, such as calcination and gas phase chemical vapor deposition. Some products can be manufactured by a combination of these two general process routes.
[0019] 1) Precipitation—General Description
[0020] Yellow, red, and black iron oxides are precipitated products that rely on careful control of a complex series of liquid-solid, gas-solid, and gas-liquid reactions. Nucleation and precipitation/crystallization kinetics are the preferred key to preparation of the correct chemical composition, particle size, particle size distribution, particle morphology, and ultimately, the desired color.
[0021] Both the yellow (goethite) and red (hematite) products are made from a modified version of the Penniman-Zoph process in which a nucleus or seed particle is grown to a target size The source of the nutrient for this particle growth is continuously provided by dissolution of iron. The iron is a specially-selected grade that is dissolved in an acidic ferrous sulfate solution and oxidized with finely-dispersed air. The primary distinction between the yellow and red processes is in the nature of the seed particle.
[0022] The following representative reactions (not balanced) depict the seed and growth (generation) stages of precipitation processes
[0023] Following the seed generation stage, the yellow or red iron oxide slurry is filtered, washed, dried, milled, and packaged. An alternative yellow and red iron oxide process is a direct precipitation route. In such a process the nutrient is a preferred iron salt solution rather than the specially selected iron.
[0024] The black iron oxide process resembles the “Seed” phase of the reactions but must be conducted at a higher temperature and pH to precipitate magnetite:
[0025] Terminal stage operations are similar to the yellow and red processes.
[0026] 2) Calcination—General Description
[0027] Solid state reactions with strict control of gas-solid equilibria characterize the calcination manufacturing processes used to prepare the red and copperas red iron oxide product lines
[0028] Calcination of yellow iron oxide is a dehydroxylation of the oxyhydroxide to yield red iron oxide as depicted in the following reaction.
[0029] The copperas reds are prepared by a process that results in a hematite with the highest chemical purity and chroma.
[0030] A purified ferrous sulfate solution is further purified during evaporation and crystallization stages. The ferrous sulfate heptahydrate crystals (FeSO 4 .7H 2 O), also known as “copperas,” are dried and dehydrated to ferrous sulfate monohydrate (FeSO4.H 2 O). The monohydrate is then oxidized during a calcination step to the hematite (α-Fe 2 O 3 ) or copperas red iron oxide particle The by-product sulfur gases are recycled to the contact sulfuric acid plant. Further purification is achieved during subsequent washing steps followed by filtration, drying, milling and packaging.
[0031] The process can be summarized by the following chemical reaction (not balanced):
[0032] The inventive process comprises mixing (e g. blending, grinding and dispersing) such high purity iron oxide pigment made as described above, or by other known processes, with water to form an aqueous composition Useful for the high purity iron oxide pigments of the invention are a family of pigments made by the assignee of this invention and sold under the TruPure trademark, for example Tru Pure R2199 AP, a red iron oxide. Rockwood Specialties makes a yellow high purity iron oxide sold under the description Y50EC also useful for this invention. Bayer GmbH makes a yellow product (920Z) also useful BASF, a large German chemical company, makes a high purity black iron oxide useful for mascara called Sicovit Black 80E172.
[0033] Useful products include red, copperas red, black, green, blue-green, yellow, brown and blends therefore. These iron oxide pigments have the following technical specification or characteristics. It is to be understood that such individual pigment particles (because of their very small size) can “clump” together to form larger pigment agglomerates
[0034] 1. Average particle size—from 0.01 to 1.30 μm
[0035] 2. Specific surface area—from 3.0 to 200 m 2 /gram
[0036] 3 Specific gravity—from 3 20 to 5.20
[0037] In order to be useful in the dispersions of this invention particularly for cosmetic, pharmaceutical, food including pet food, tobacco and personal care customers, these products must critically contain pigment with substantially lower maximum levels of impurity levels than normal as follows:
[0038] 1. Not to exceed 20 ppm lead preferably not to exceed 10 ppm
[0039] 2. Not to exceed 5 ppm arsenic preferably not to exceed 3 ppm
[0040] 3. Not to exceed 3 ppm mercury preferably not to exceed 1 ppm
[0041] Useful high purity iron oxide particles are formed using known techniques such as previously described, such that the resultant pigments have acceptable, i e., reduced, levels of trace metals such as arsenic, mercury and lead. These levels are substantially lower than those found in iron oxide sold for use in the paint and coatings industry for example, where toxicity is not a primary concern. Pigments, having the requisite levels of these trace metals for use in the present invention, are therefore referred to in the present specification as substantially “pure” or as “high purity” This substantially “pure” material is suitable for application to human skin since the trace metal content is maintained at or below the levels set forth above, that is, below levels which are very, very unlikely to cause dangerous effects in humans or animals.
[0042] Dispersants and other chemicals may be added to the inventive aqueous compositions including grinding aids such as glycerine, preservatives such as potassium sorbates, citric acid and combinations thereof to produce sorbic acid, anti-settling additives, wetting agents such as lecithin, flavor ingredients, other pigments such as zinc oxide and titanium dioxide, and rheological additives just for example. Preservative—containing dispersions are preferred The dispersions should as a rule not contain appreciable amounts of organic solvents such as propylene glycol, xylene, toluene, or herbicides and biocides.
[0043] In a preferred embodiment, applicants' substantially pure iron oxide particles are formed having a substantially spherical shape. A variety of other shapes, such as acicular, oval and rhomboids have also been found to provide acceptable cosmetic use, however, any shape may be utilized in the formulations of the invention as well, although as noted above, spherical particles are the most preferred.
[0044] The “purity” of these iron oxide pigments renders formulations containing this material suitable for application to human skin without danger due to transdermal absorption of trace metals. It also permits use in foods of an ingredient of great safety and effectiveness in providing color to such formulation In addition the invention provides an aqueous vehicle of great pumpability and flowability to permit a customer flexibility in manufacture without the safety or environmental risks involved in the handling of powder.
[0045] The substantially pure iron oxide particles are incorporated into a aqueous dispersion preferably with one or more preservatives Such dispersions may then be incorporated by known mixing methods into a variety of cosmetic products such as lipstick, eyeshadow, foundations, moisturizers, rouges and the like to form cosmetics having an increased acceptance to discerning health-oriented customers. They are also particularly useful for food and pet food companies who want to impart coloring to their products to provide, for example, a “meaty look” for dog and cat food without any likelihood of harm to pets.
[0046] Iron oxide particles of the size and morphology described herein, with such reduced levels of trace metal contamination, have been previously known in the art Dispersions of low purity iron oxide pigments in water have also been known since at least the early 1900's and “relatively” high purity type iron oxides has been available on the market since the 1930's. It is speculated that persons in the art believed that adding such iron oxides to water would result in an unpure dispersion because of the generation of harmful acids It is also believed that chemists working in the field thought that undesirable side reactions of the iron oxide would occur in water decreasing their purity and that a liquid dispersion in water would promote the formation of mold, fungus, or microbial activity.
[0047] There is no teaching or suggestion that applicants are aware of to utilize iron oxide particles of the type described herein in an aqueous dispersion for applications such as those contemplated by applicants, namely as a component of: 1) cosmetic formulations, 2) food compositions, 3) pharmaceuticals and 4) pet foods particularly foods made for cats, dogs and other domestic animals capable of providing an enhanced degree of satisfaction. Thus the use of applicants' pure iron oxide dispersion in the manner indicated provides unexpected results with regard to the ability of this material to afford the customer both ease of handling and satisfaction of having met all environmental concerns
EXAMPLE I
[0048] In this Example, the percentages stated are by weight based on the weight of the pigment used. The following steps are used to illustrate the invention herein.
[0049] Step 1—Mixing
[0050] Components:
[0051] 1. 5-80% by weight (preferably 20-60%) high purity iron oxide pigment (red, yellow, black, brown or blends).
[0052] 2. 20-95% by weight of water.
[0053] 3. 0-5% by weight (preferably 3%) of one or more preservatives
[0054] 4. 0-15% by weight (preferably 8%) of one or more dispersants.
[0055] 5. 0-15% by weight (preferably 8%) ofone or more anti-settling additive.
[0056] Iron oxide was loaded into a media mill where liquid mixture of water and other ingredients were added. Mixing preferably occurs using a high-speed disperser or media mill; time of mixing preferably 5 minutes to 30 minutes; 100 to 3000 revolutions per minute if a high speed disperser is used
[0057] Discussion of Results:
[0058] The result is a high purity iron oxide dispersion that meets FDA specifications for food, pet food, cosmetics, pharmia, and personal care. It will also meet specifications for European directive E-172. The improvements include:
[0059] Allows for batch to batch uniformity.
[0060] Better color work up with less pigment 10-30% less pigment
[0061] No dusting.
[0062] No cross contamination of equipment or raw materials.
[0063] Less labor intensive
[0064] hookup pump
[0065] no clean up
[0066] economical process
EXAMPLE II
[0067] The following example shows the manufacture of a aqueous dispersion according to this invention designed to be particularly useful for pet foods.
Red Pigment Dispersion for Pet Food Raw Materials grams % Observations water 75 21.60 shear thins glycerine 99.7% 12 3.50 no syneresis Turn on disperser no settling Thermolec WFC 25 7.20 High speed grind for 10 minutes 500 rpms High Purity Red Iron Oxide 225 64.90 Slowly add pigment-This may take up to 60 minutes Grind for 30 minutes (1500-2000 rpms) potassium sorbate preservative 2.8 0.80 25% wt. Soln. Let down, grind 10 minutes citric acid preservative 25% wt. Soln. 6.8 2.00 (add drop-wise) Grind for 10 minutes (1500-2000 rpms) 346.6 100.00
[0068] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof | An aqueous composition comprising water and high purity iron oxide preferably including a preservative is described. The composition is useful as a coloration ingredient in pharmaceuticals, cosmetics, foods, pet foods, and tobacco products which can be incorporated as a liquid conveniently into system of customers that desire a liquid high purity iron oxide ingredient or have been convinced to change from a dry high purity iron oxide ingredient to obtain the benefits of a liquid system. | 2 |
BACKGROUND OF THE INVENTION
A longstanding continuing need has existed for a truly effective speed changing device for mechanical systems, particularly those which are gearless, commonly referred to as traction drives. Most available traction drive systems are limited to a speed change ratio in the order of 10 to 1, and even with such a low ratio do not exhibit the properties of low backlash, high torque capacity and high efficiency.
Often, traction drive devices employ epicyclic drive members with a series of planetary members encircling a sun member. Rotational motion is transmitted via the sun member with highly concentrated loading on the surface of the sun member. Torque is limited in such systems, the system tends to have lower efficiency than is desired and the energy lost is converted to heat in the region of the sun member at the innermost region of the system and difficult to remove. Such systems also exhibit a significent amount of backlash unless they are loaded so severely that efficiency suffers.
A number of prior researchers have attempted through the years to improve traction drive systems and in the process have improved one characteristic, usually at the sacrifice of other parameters of the system.
Desired is a traction drive system which achieves all of the following:
1. A high speed change ratio, e.g. up to and greater than 100:1;
2. Low backlash;
3. Linearity of speed between input and output;
4. High efficiency;
5. Easily cooled;
6. High torque capability;
7. Balanced loading within the system;
8. Freedom from harmonics; and
9. Concentricity of input and output.
Additionally, it is often desired that an annular configuration be possible for the drive system.
Heretofore, the geared system has been selected where high torque transfer is required and high speed change ratio desired. The geared system, however, has inherent backlash which eliminates its use where precision non-backlash is needed or where freedom from harmonics is essential. Examples of geared speed change systems are shown in the following U.S. patents:
______________________________________4,228,698 M. E. Winiasz October 21, 19804,155,276 W. H. Fengler May 22, 19794,016,780 S. J. Baranyi April 12, 19773,424,036 W. L. Colgan Jan. 29, 19693,330,171 A. L. Nasvytis July 11, 19673,442,158 E. Marcus May 6, 1969______________________________________
Where harmonic suppression and reduced backlash is desired at the loss of torque handling ability, the traction drive has been adopted. Examples of such systems appear in the following U.S. patents:
______________________________________4,128,016 A. L. Nasvytis Dec. 5, 19784,112,787 H. Tippmann Sept. 12, 19783,941,004 C. E. Kraus March 2, 19763,889,554 B. J. Sinclair June 17, 19753,848,476 C. E. Kraus Nov. 19, 19763,254,546 A. L. Nasvytis June 7, 19663,286,550 C. Rosain et al Nov. 22, 19663,216,285 A. L. Nasvytis Nov. 9, 19652,837,937 C. E. Kraus June 10, 19582,656,737 G. L. Lang Oct. 27, 1953______________________________________
Each of these systems offer the general advantages of traction drives but exhibit the traditional limitations of traction drive systems outlined above. Continued research to the date of my invention has failed to meet the full needs for traction drives.
BRIEF DESCRIPTION OF THE INVENTION
Basically my invention involves an annular bearing surface in which a pair of rollers of diameter smaller than the annular surface are journaled for rotation. The rollers are connected to each other by a crank having a crank arm slightly greater in length than the difference between the roller diameter and the annular bearing surface. The crank causes the rollers to engage the annular bearing surface at diametrically opposed positions. Means are provided to introduce hypocyclic motion into one roller and extract rotary motion via a second crank or spider coupled to a shaft. The device produces a change in speed therethrough which is a function of the difference in diameters noted above. The device provides large speed changes, linearity between input and output shafts and high torque carrying capability. The rollers and interconnecting cranks comprise a binary synchronous eccentrically coupled roller assembly.
In a first embodiment the rotational motion is introduced and extracted via axially aligned shafts. In a second embodiment, the rollers are themselves hollow and the entire assembly is annular.
BRIEF DESCRIPTION OF THE DRAWING
This invention may be more clearly understood from the following detailed description and by reference to the drawing in which;
FIG. 1 is a perspective view, partly broken away, showing the basic combination of this invention;
FIG. 2 is a transverse sectional view of an embodiment of this invention;
FIG. 3 is a longitudinal diametrical view of the embodiment of FIG. 2 taken along lines 3--3 of FIG. 2;
FIG. 3A is an exploded view partly in section of the combination of FIG. 3;
FIG. 4 is a longitudinal diametrical view of an annular embodiment of this invention; and
FIG. 5 is a transverse sectional view of the embodiment of FIG. 4 taken along line 5--5 of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
For an understanding of my invention, attention is directed to FIG. 1 which constitutes a perspective view with portions broken away of a speed changer in the order of 100 to 1, and in one embodiment, is 4 inches in diameter, 31/2 inches in length and has input and output shafts of 0.25 inch and 0.50 inch respectively with a maximum permissible torque capability of 400 inch pounds. The embodiment of FIG. 1 illustrates the principle of this invention and is useful in applications such as servo systems with low backlash requirements, high speed machinery such as gas turbine systems, and harmonic or vibration sensitive precision drive systems such as photographic emulsion coating machines.
Referring now to FIG. 1, the speed changer, generally designated 10, includes a stator or load ring 11 which defines an internal annular bearing surface 12 upon which a pair of internal hypocyclic roller members 13 and 14 are positioned. The rollers 13 and 14 have a difference in diameter from the diameter of the bearing surface 12 which constitutes a measure of the speed change of the device in accordance with the following formula: ##EQU1## SC is negative to indicate direction reversal since the denominator is always negative with the roller diameter less than its encircling annular stator surface.
Where SC is the speed change ratio between the input and output shafts, D R is the diameter of the hypocyclic roller and D S is the diameter of the annular stator surface.
The roller 13 is in fact a dual or compound roller including two parts, each of the same diameter, namely roller part 13A and roller part 13B coupled together by hub 13C. The roller parts 13A and 13B are each respectively coupled to the roller 14 by individual crank arms represented by the single crank member 15 appearing in FIG. 1 which is journaled in the roller 13B by bearing assembly 16 and journaled in the roller 14 by roller or ball bearing assembly 20. Similar equally spaced crank arms 21 and 22 appearing in FIG. 1, each having the same offset as arm 15 as illustrated in the broken away portion of the roller 13B, allow hypocyclic movement of the rollers 13A, 13B and 14 with respect to the stator 11, each bearing upon the inner surface 12 of the stator 11 at diametrically opposed positions on the surface 12. The rollers 13 and 14 as may be seen in FIGS. 1 and 3 are smaller in diameter than the load ring 11 but have diameters greater than half the diameter of the annular surface 12 to allow for the presence of the cranks employed in this invention.
21 and 22 of FIG. 1 also couple the roller part 13A to the roller 14. The offset of the roller part 13A with respect to roller 14 is identical with that of roller part 13B whereby the areas of contact of the rollers 13A and 13B coincide radially on the surface 12 but are axially displaced and diametrically opposed to the position of the area of contact of the roller 14 on the bearing surface 12. This is more clearly illustrated in FIG. 3.
The roller 13 is coupled at its part 13B to a high speed lower torque shaft 23 which is eccentrically mounted with respect to a crank member 24 which in turn is rotatably positioned within a central opening in the roller part 13B by bearing assembly 25. The eccentricity of the crank member 24 matches the eccentricity of the roller 13. The eccentricity of the bearing or crank member 24 is equal to one-half the difference in diameters of roller surface 12 and roller 13 or 14. The eccentricity may be defined by the equation:
E.sub.S =1/2(D.sub.S -D.sub.R) +A (2)
where
E s=the eccentricity of crank member 24; and
A =preload dimension.
(The numerical value for "A" is a designer decision base on trade-offs including the input speed, output torque, stator compliance, efficiency, unit life and material selection. The prototype unit successfully used a value of 0.005 for "A".)
The same criteria apply to a second or low speed shaft 30 coupled to the roller part 13A in the manner as is disclosed in FIG. 3.
In FIGS. 1 and 3A, the shaft 30 is shown as having a larger diameter than shaft 23 since it constitutes the low speed, i.e. high torque end of the system. They both, however, may be of the same diameter. Of most importance is the fact that the shafts 23 and 30 are axially aligned so that the speed changer is an aligned shaft device enhancing its suitability for many applications. Offsets within the device are due illustrated in FIGS. 3 and 3A by the jogged centerline.
As disclosed in FIGS. 1 and 3A, a rotational movement of shaft 23 produces opposite direction rotation of shaft 30 at a fixed speed ratio as determined above.
In FIG. 1, the speed changer 10 is simplified for ease of comprehension of the fundamental elements of the invention. For a more complete understanding, attention is directed to FIG. 3A and particularly FIG. 3, the latter of which is a longitudinal sectional view taken along line 3--3 of FIG. 2 to which reference is also made.
The embodiment of FIGS. 2 and 3, in addition to the operating elements of FIG. 1, includes an outer housing generally designated 40 including an outer annular wall 41, a pair of end plates 42 and 43, a low speed shaft bearing assembly 44, and a high speed bearing assembly 45. The eccentric links 63 have an offset or crank arm length equal to one half of the crank arm length of crank 21 as denoted in the drawing FIG. 3 by the difference in offset of the axes of their respective bearings.
Reviewing the system of FIG. 3 from the high speed shaft 23A end, we find that shaft 23A is journaled in bearings 45 of the outer housing and includes a tooth coupling 46 within the housing 40 coupling the high speed shaft 23A to roller shaft 50 which includes the eccentric 24. Note that the axis of shaft 50 is displaced from the aligned axes A--A of shafts 23 and 30. Journaled on the shaft 50 by a bearing 25 is the roller 13 with its two parts 13A and 13B engaging the bearing surface 12 at the lowermost point in FIG. 3. The loading ring 11 with its annular bearing surface 12 is located within the housing wall 41 by spacer rings 51 and 52 at the high speed and low speed sides of the assembly. Ring 11 is restrained from rotation by one or more key, one of which 11A appears in FIG. 3A.
In accordance with one feature of this invention, the cavity 53, formed between the outer wall 41 and the bearing member 11 may be fluid filled for efficient transfer of heat energy from the drive to the exterior of the housing 40. Additionally, the free unsupported section of the bearing member 11 between the spacer blocks 51 and 52 allows the bearing pressure applied by the rollers 13 and 14 to slightly distort the bearing surface 12 outward to provide more than line contact between the respective rollers and the bearing surface 12. This allows greater torque to be transmitted through the device, and by reason of the void 53, efficient cooling may be accomplished.
Roller 14 is coupled to roller 13 via a plurality of cranks, one of which, 21, appears in section in FIG. 3 with end shaft portions 60 and 61 coupled respectively to the roller portions 13A and 13B via bearings 62 and 18. The roller 14 engages the surface 12 at a diametrically opposite point from roller 13 as is illustrated particularly in FIG. 3. It is journaled by bearing 62 beyond shaft 21 and an additional number of bearing assemblies such as 16 and 20 of FIG. 1. Note that there is no additional spring member present in the system as described, relying principally on the resiliency of the bearing member 11 for any compliance in the system. This allows far greater torque to be transmitted through the system than devices heretofore.
The roller 13B is additionally coupled by a plurality, for example, three, eccentric links, one of which is shown in section, namely, 63, to a spider 64 which is secured to output shaft 30 by set screw 65. Shaft 30 is journaled in the housing 40 by bearing assembly 44. The links or crank member 63, the spider 64 and the shaft 30 together constitute a parallel link coupling to produce pure angular rotation of shaft 30.
By employing the arrangement of FIGS. 1-3, speed changes between the two aligned shafts of 100:1 or more are easily acomplished with virtually no backlash between the shafts 23 and 30. The drive system is preloaded and the traction elements engage each other, namely rollers 13 and 14, and annular track 12 at relatively large diametrically spaced positions. Thus, balanced loading of relatively low per unit area exists at the contact surfaces of the device. This is in marked contrast with epicyclic devices which encounter high localized loading on a central sun member.
The preloading is achieved merely by the resiliency of the annular member 11. This member 11 is easily cooled, again in contrast with epicyclic systems.
In certain embodiments a speed changer is desired in an annular drive system, for example in the mount of a shipborne radar antenna system which requires the central column for transmission lines. Precise positioning is a requirement of such systems.
This invention is easily adapted to an annular or torque tube configuration. Such an embodiment is shown in FIGS. 4 and 5. Referring to FIGS. 4 and 5, a hollow drive system is disclosed containing its own drive or torque motor and a tachometer whereby the system is ready for direct integration into a servo system, for example a radar antenna mast with clearance room for the antenna feeds such as wave guides which pass through the central opening undisturbed by the drive system.
In FIGS. 4 and 5, a hollow high speed shaft 22 is shown timing its interior opening 22A which extends through the drive system to an aligned central opening 23A in hollow low speed shaft 23. The high speed shaft is encircled by a D.C. torque motor 29 and a D.C. tachometer 30. The torque motor drives the high speed shaft within the enclosing housing of the assembly made up of the drive housing 27 and the motor tachometer housing 28. The high speed shaft 22 is journaled in high speed shaft bearings 34 engaging an outer stepped flange 34A at the high speed end of the motor tachometer housing 28. The high speed shaft 22 is journaled at its inner ends by roller shaft bearing 35, which is eccentrically mounted on shaft 22, itself journaled in compound or dual roller 24 including a high speed end roller member 24A and a low speed end roller portion 24B. Eccentric link 31, which has a central offset, engages rollers 24A and 24B each end and engages reaction roller 25 at the central offset. As in the case of the embodiment of FIGS. 1-3, the compound roller 24 engages at one side of the annular surface 26A of the loading ring or stator 26 secured within the housing 27 by a plurality of (e.g. 4) anti-rotate keys 36. The two compound roller parts 24A and 24B again engage the loading ring 26 at a diametrically opposed position from the engagement of the reaction roller 25.
In FIG. 4, the compound roller 24 engages the loading ring at the top of the figure and the reaction roller 25 engages the loading ring at the bottom of the figure. In addition to the eccentric link roller 31 appearing in FIGS. 4 and 5, similar eccentric links 32 and 33 spaced at 120 degrees around the periphery secure the compound roller 24 and reaction roller 25 for synchronous angular rotation together subject to the axially displacement resulting from the offsets of each of the eccentric links 31, 32 and 33.
The angular rotation of the compound roller 24 is transmitted to a spider 37 in the form of a plurality (e.g. 3 or more) arms formed integrally with the hollow output shaft 23 engaging the compound roller part 24B at three equally distant spaces via spider eccentric links 32A, 33A and 31A. The low speed shaft is journaled in housing 27 by low speed shaft bearing 38.
Given the above described combination of FIGS. 4 and 5, each of the advantages of large speed change balance loading low backlash and linearity of speed changes accomplished and the system includes provision for in general driving, and speed monitoring while maintaining a clear annular opening. This design is particularly adaptable to the annular configuration since the larger the opening along the axis, the greater speed change ratio is possible, the greater torque transmition is possible and the lower the loading forces as compared with previous drives.
The above described embodiments are merely representative of the principles of this invention and are not to be considered as limiting. Rather this invention is defined by the following claims including their equivalents. | A traction drive and speed changing device with a pair of aligned shafts extending out of opposite ends of a housing and in alignment. Contained within the housing is an internal race or annular bearing surface. A pair of rollers, each of lesser diameter than the race are interconnected by a first crank which maintains the rollers in frictional engagement with the race. A second crank couples the first roller to the input shaft. A third crank couples the first roller to the output shaft. A speed reduction related to the difference in diameters of the roller and the race. An annular version suitable for providing speed changes for a rotating body and to allow cables or conduits to pass through the device. | 5 |
BACKGROUND OF THE INVENTION
The present invention pertains generally to isotope separation and in particular to laser-induced separations of hydrogen isotopes.
The objective of laser-induced separations of isotopes is to selectively transform molecules of one isotope into an enriched chemically distinct species which is capable of being chemically separated by subsequent processing and hence enriched. Generally, this type of isotope separation involves a preferential vibrational excitation of molecules of the desired isotope, followed by a chemical reaction, a uv photodissociation, or photoionization.
Even if molecules containing a certain isotope absorb energy preferentially, isotopic specificity can be destroyed by intermolecular VV energy exchanges between the various isotopically substituted species or by bulk heating. Interisotope VV transfer is near-resonant and therefore very fast, typically on the order of ten gas kinetic collisions. For a given molecule, it is very difficult to find a reaction which proceeds at a rate comparable to a VV transfer, simultaneously shows appreciable vibrational enhancement and yields a product which does not undergo a rapid chemical isotope exchange with the reagents. Bulk heating, due to VT relaxation of the excited species, increases the rate of the nonselective thermal reaction and therefore can completely mask the vibrational component of the reactivity change.
Besides isotopic specificity, an isotope separation must have several additional characteristics in order for it to have any commercial potential. Due to energy costs, isotopic spcificity occurring at excitations among the lowest two or three vibrational levels is most desirable. The separation must also be pressure scalable to be commercially viable. In other words it must be able to operate over a wide range of pressure, particularly pressures above those typically employed in the resarch laboratory.
Laser-induced separations involving spontaneous photodissociations due to vibrational excitation of low-lying vibrational levels are few. Large fractionation ratios are disclosed for the decomposition of D 3 BPF 3 and H 3 BPF 3 in K--R Chien and S. H. Bauer, J. Phys. Chem. 80(13), 1405 (1976). This method utilizes a direct absorption of photons by a costly reagent and thus can only proceed if a laser can operate at the absorption band and if no excessive bulk heating of the reactant occurs.
The separation techniques disclosed in U.S. Pat. No. 4,097,384 issued to Coleman et al on June 27, 1978, includes dissociating an uranium ligand as well as the more common scheme of a subsequent preferential reaction of the selectively excited molecules with another reactant. This method also relies on a direct absorption of photons to obtain a vibrational excitation of the molecules and has the same problems previously discussed. The necessity of having a laser operate in the fundamental absorption band of the molecule being excited is attempted to be solved by relying on absorptions at the overtones. These absorptions are relatively small and thus scalability to larger systems is difficult.
The separation method in S. W. Mayer, M. A. Kwok, et al, App. Phys, Lett. 17, 516 (1970) is another direct absorption method. An H:D separation is achieved through an isotopically specific reaction in a CH 3 OH:CH 3 OD:Br 2 gas-phase mixture at a pressure of about 100 torr which has been excited with a 90 w cw HF laser. All attempts to reproduce the results have failed, due probably to bulk heating of the gas mixture, VV transfer, and chemical isotopic scrambling between reagents and products.
As was stated previously, a major cause for failures of isotope separation attempts is the rapid rate of intermolecular VV energy exchanges between isotopically substituted species exceeding the rate of the chemical differentiation step. This whole question has been left unanswered in previous research work. It has been pointed out that if the total rate of deactivation of the excited vibration is comparable to or faster than the rate of interisotopic VV exchange, isotopic selectivity on a CW basis is preserved as well as establishing pressure scalability. This concept has been termed the competing-deactivation technique. In Manuccia et al., J. Chem. Phys. 68(5), Mar. 1, 1978, this technique is used to enrich 79 Br or 81 Br in the products of the radical chain reaction of chlorine atoms with natural isotopic-abundance methyl bromide by exciting the respective CH 3 Br in a low-pressure, discharge flow reactor intracavity to a CO 2 laser.
A deuterium separation by the competing-deactivation technique is disclosed in Hsu et al Advances in Laser Chemistry, ed. by A. H. Zewail, Springer Series in Chemical Physics, p. 88-92, and in Hsu et al Appl. Phys. Lett. 33(11), p. 915-17, (Dec. 1, 1978), A CW CO 2 laser is used to vibrationally excite CH 2 D 2 in a mixture of CH 2 D 2 and CH 4 while an intentional VT deactivation by argon atoms and the reactor walls competes with interisotope VV transfer to produce a gas sample in which the CH 2 D 2 is excited and the CH 4 remains less excited on a steady state basis. A reaction of this gas mixture with chlorine atoms and molecules forms a stable product, deuterated methyl chloride, enriched in deuterium by up to 72%. This method can be considered technically important because it is the most energy efficient laser method for deuterium to date. The projected energy efficiency, however, is below that of the current H 2 S/H 2 O process because of the high energy costs of pumping, refrigeration and reactant regeneration imposed by use of the thermoneutral reaction.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to separate hydrogen isotopes using an inexpensive and readily available feedstock by a highly energy efficient, pressure-scalable process having a high enrichment factor.
A further object of this invention is to excite, at moderate laser fluxes and in reasonable path lengths, isotopic forms of reagent molecules which could not be excited directly by a laser.
A still further object of the present invention is to produce isotopical selective excitation by energy not coming from lasers.
These and other objects are achieved by imparting vibrational excitation to sensitizer molecules, transfering the vibrational excitation to a mixture of normal and deuterated alkanes, whereby the deuterated alkane is preferentially excited, reacting the alkane mixture with bromine atoms, and separating the deuterated end products.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing of the apparatus used in demonstrating the effectiveness of the present technique for separating hydrogen isotopes.
FIG. 2 is a graphic illustration of the wall-temperature dependence of deuterium enrichment factor in the Br+CH 2 D 2 /CH 4 reaction sensitized by CO 2 .
FIG. 3 is a graphic illustration of the effect of the total cell pressure with fixed methane mole fraction on the enrichment factor in the Br+CH 2 D 2 /CH 4 reaction sensitized by CO 2 .
DETAILED DESCRIPTION OF THE INVENTION
It is theorized that during the present isotope separation, using CO 2 as the isotopically selective vibrational sensitizer molecule and methane as the feedstock, the following reactions occur: ##EQU1##
The bromine atoms also react thermally with ground-state methane molecules to a small extent at temperatures below 160° C. In the above reactions, k 1 is greater than k 2 , which results in a greater degree of initial vibrational excitation (faster temperature) in CH 2 D 2 than in CH 4 . The higher and lower vibrational temperatures are indicated by "V" and "v" respectively. Deuterium enrichment then results because k r 1 exceeds k r 2 . It is noted that the branching ratios for the two reactions in (3) are approximately equal because of moderate classical kinetic isotope effects and participation of both C--H and C--D bonds in vibrational excitation of the small CH 2 D 2 molece. It should also be noted that both the hydrochloric acid and methyl bromide products of reaction (3) must be collected for an efficient application of this process.
The relative rates of these various reactions are established by the usual to the VT-competing deactivation processes, in addition to VVT-competing deactivation processes which occur in the overall reaction as a result of the presence of large amounts of CO 2 sensitizer and molecular bromide. All of these deactivation processes compete with VV interisotope energy transfer preserving the initial excitation selectivity and contributing to the higher degree of steady state vibrational excitation in the deuterated methane than in normal methane.
The above discussion is only a partial explanation of the complex chemistry of the present invention. It is given by way of a possible explanation of the present invention and is not intended to limit the invention to any specific theory. It should be noted that for any reaction scheme to effect an isotope separation, these reactions, along with all of the excitation, transfer of excitation, deactivation, and reaction events occurring between the introduction of the reactants with the reactor and the formation of products, must produce an accumulation of isotope effects which results in a segregation of isotopes, a result being entirely unpredictable a priori.
In practice, an isotopically selective vibrational sensitizer gas, a deactivating gas, atomic bromine, and a mixture of a protonated alkane and one or more of its deuterated species are introduced into a reaction system. The sensitizer gas can be excited to higher energy levels either before or after its introduction into the reaction chamber. The reaction system has a temperature from about 90° to about 220° C. with a preferred range from 100° to 200° C., a total pressure from about/0.5 Torr to about 10 4 Torr with a commercially preferred range from 10 2 to 10 4 Torr, and a reactant partial pressure from about 7×10 -3 to about 5×10 3 Torr with a commercially preferred range from 50 to 500 Torr.
The vibrationally excited sensitizer molecules transfer their energy preferentially to vibration in the deuterated alkane molecules and not the undeuterated species, thus acting as an isotopically selective vibrational sensitizer molecule, a new concept. Due to the competing deactivation processes present in the reaction system, the deuterated alkane molecules remain more highly excited than the normal alkane molecules on a steady-state basis and accordingly react, with bromine atoms at a faster rate than protorated alkane molecules.
The process of this invention can be easily operated on a continuous basis rather than on a batch basis. The gases are pumped, at the above pressures, through a flow cell which is maintained at the above temperatures by, e.g., an oven. Adjustment of the operating parameters of the process would be based on economic optimization considerations, balancing throughput, energy, and reagent costs against enrichment factor and reaction rate choice. The size and shape of the flow cell depend on the power and output beam quality of the laser, if a laser is used to excite the sensitizer molecules, in situ, the volumetric flow rate and the operating pressure. Any shape and size which provides a uniform flux and allows a saturated or nearly saturated vibrational energy content of the sensitizer gas can be used. If the flow cell is constructed of a material, (e.g., pyrex), which promotes recombination of bromine atoms, it is to be coated with a substance which inhibits atom recombination (e.g., phosphoric acid).
The present technique permits a great latitude in designing the reaction system. Total and reagent partial pressures and flow rates, laser power, and reaction systems design are all interrelated and vary greatly. A few sample runs of any system would quickly determine the conditions which would most economically produce saturation, i.e., the point at which the enrichment does not increase. For example, a low total flow rate and pressure would require a small laser flux and thus little energy to reach saturation, but the throughput would be extremely small, thereby requiring a long run and therefore much energy and time to obtain the desired amount of isotope.
The laser, if a laser is used to excite the sensitizer molecules, should, of course, match the absorption of the sensitizer. A multiple-line or mode or a single-line or mode laser can be used. As stated above, the power of the laser should be sufficient to nearly saturate the absorption which requires a power density of about 1 to about 10 3 watts/cm 2 for laboratory-scale experiments and appropriately larger values for commercial pressures and flow rates. A cw CO 2 laser is preferred. The preferred location of the laser is external to the flow cell for commercial operations; however, any other arrangement which provides a uniform and sufficient irradiation can be used, e.g., inracavity or multiple lasers).
The stable end products (deuterium bromide, hydrogen bromide, alkyl bromide, and deuterated alkyl bromide) are enriched in deuterium. They can be separated by any standard chemical fractionization process, i.e., by a method comprising a scrubbing with water and a partial liquidification of the gas stream.
The alkane reagent (the feedstock) for the reaction of this technique is a mixture of an alkane with one to four carbon atoms and its deuterated species. The deuterated species must closely match while the protonated species does not. For the initial feed, the preferred mixture is one of the above with a natural abundance of the deuterated species. Due to the inexpensiveness and the availability of natural methane, methane with a natural abundance of deuterated methane is most preferred. It is, of course, possible to have an alkane with any level of deuteration as the feedstock.
Bromine atoms can be produced by any type of dissociation techinque, e.g., by an rf discharge or by a laser. The bromine atoms can be generated before their introduction into the reaction site or they can be generated in situ in the reaction mixture by irradiation with a laser operating in the dissociative visible absorption band of bromine. The amount of molecular bromine can vary widely, depending on the exact method and parameters of the dissociation process used and the wall-recombination rate, so as to limit the consumption of 13 CH 3 F to 10 to 60%. If the amount is about the stoichiometric amount or less, the output is usually seriously reduced. The amounts preferred, for economic and other reasons, are typically from 10 to 100 times the stoichiometric amount, based on a single substitution.
The reactants are mixed with a deactivating gas so that the VT and VVT deactivation rates are faster than the VV interisotopic energy transfer. The deactivating gas may be any gas inert to the ongoing chemical reaction and nonabsorptive to the laser irradiation. Examples of a deactivating gas are sulfur hexafluoride (SF 6 ), nitrogen, and the noble gases. Regardless of whether the process is batch or continuous the volume percent of the deactivator is from 1 to 95 percent depending on the VT and VVT rates of the deactivation, its heat transfer properties, and the exact mechanical configuration of the system.
If bulk heating or insufficient flow velocity is encountered, it may be advantagous to have independent control of these parameters by the addition of a diluent gas. A diluent gas is inert to the ongoing chemical reaction, does not absorb the laser irradiation, and has a slow deactivation rate constant. With some intermediate gases, e.g., argon, they can be used as both a deactivator gas and a diluent gas, unlike krypton which can only be used as a deactivating gas.
The sensitizer gas must promote the vibrational chemistry of the subject process with isotopic selectivity by transferring its vibrational energy to one of the feedstock constituents. This is possible if the configuration of the energy levels of the sensitizer-gas molecule more closely approximates that of one of the feedstock components. The preferred sensitizer gas is carbon dioxide, but carbon monoxide, nitrogen, or oxygen, can also be used. The excitation energy available in the sensitizer molecule can be higher than the energy of the laser or radiation because the sensitizer can be prepared in highly excited states by conventional means or by hot-band laser absorption. Nitrogen or a nitrogen--CO 2 mixture of at least 30 percent CO 2 is best suited for excitation by non-laser means, which for nitrogen is by electrical discharge techniques. The total amount of sensitizer gas, i.e., the amount necessary to vibrationally saturate the corresponding transition of the deuterated alkane, is preferably about equal to the amount of the deuterated alkane.
The following examples use a reactor system as shown in FIG. 1. The flow reaction is a 1.0-m-long, 24-mm-i.d quartz tube, coated internally with phosphoric acid, surrounded by an oven, and positioned intracavity to a conventional low-pressure, longitudinal-flow cw CO 2 laser. The methane and bromine reactants are premixed with the CO 2 sensitizer and an argon carrier gas. The entire mixture is injected at one end of the flow cell. The beam of the argon ion laser, which operates in the multipleline mode, is introduced to the flow reactor by means of reflection from a germanium plate. With the CO 2 laser on any line in the 9- or 10 μm bands, vibrationally excited CO 2 molecules are produced in the flow reactor by hot-band absorptions on the usual laser transistions. Collisional pumping can further produce even higher excited states.
A quadrupole mass spectrometer (not shown in FIG. 1) working in combination with a two-channel boxcar integrator with an internal rationmeter, is used to monitor any two product mass amplitudes and determine their ratio as the laser is cycled on and off. For the CH 2 D 2 --CH 4 system, the hydrogen-deuterium isotope ratio in the reaction products is determined by monitoring the amplitude ratio ρ of the parent peaks at m/e=94 and 96:
ρ=[CH.sub.3.sup.79 Br]/([CHD.sub.2.sup.79 Br]+[CH.sub.3.sup.81 Br])
For the CH 3 D--CH 4 system the ratio of [CH 3 79 Br] to [CH 2 D 79 Br] parent peaks was monitored. These ratios can be translated into enrichment factors according to the following definition: ##EQU2##
The following exaples are given to better illustrate the practice of the present invention and are not intended to limit the disclosure or the claims to follow in any manner.
EXAMPLE I
CH 2 D 2 --CH 4 +Br 2
The reagent flow rates are 0.5 Torr cm 3 , sec 1 of CH 2 D 2 --CH 4 (in a 1:1 ratio mixture), 8.9 Torr cm' sec' of Br 2 , and 42 Torr cm' sec -1 of Ar. For these flow rates, the total pressure in the flow reactor was 1.85 Torr, which implies a CH 2 D 2 partial pressure of 7 mTorr and a mean flow velocity of 0.07 m/sec. The temperature of the reaction is kept below 200° C. Only a moderate value of deuterium enrichment, on the order of 43% is obtained.
EXAMPLE II
CH 2 D 2 --CH 4 +Br 2 with CO 2
The reagent flow rates are 0.5 Torr cm' sec of CH 2 D 2 --CH 4 (in a 1:1 ratio mixture), 8.9 Torr cm 3 sec -1 of Br 2 , 12 Torr cm 3 sec -1 of CO 2 , and 42 Torr cm 3 sec -1 of Ar. For these flow rates, the total pressure in the flow reactor was 1.85 Torr, which implies a CH 2 D 2 partial pressure of 7 m Torr and a mean flow velocity of 0.07 m/sec. The temperature of the reaction is kept below 200° C. The enrichment is on the order of 70%, a considerable improvement over Example I.
EXAMPLE III
CH 2 D 2 --CH 4 +Br 2 with CO 2 v. Wall Temperature
To illustrate the effect of Wall temperature on the enrichment process, Example II was repeated at wall temperature from 90° to 270° C. The results are given in FIG. 2.
EXAMPLE IV
CH 2 D 2 --CH 4 +Br with CO 2 v. total gas mixture pressure
To illustrate the effect of increasing the total of the pressure of the gas mixture on the enrichment process, the total pressure of the reaction mixture is increased, while the proportions of the individual gases are kept fixed. The laser power, and wall temperature remain unchanged. The results are given in FIG. 3.
EXAMPLE V
CH 3 D--CH 4 +Br 2 with CO 2
The process of Example II is repeated except that monodeuterated methane is substituted for dideuterated methane. A deuterium enrichment of 83% at a wall Temperature of 118° C. is obtained.
The large improvement in deuterium enrichment in Example II results entirely from the inclusion of carbon dioxide in gas reaction mixture. As was discussed previously, the large increase is thought to be predominantly due to isotopically selection vibrational-to-vibrational (V--V) energy transfer from CO 2 -laser-excited carbon dioxide molecules to the dideutermethane, which in turn is reacted with bromine atoms at a faster rate than normal methane. A qualitative explanation for the higher degree of vibrational excitation in the deuterated methane than in normal methane is the close matching of their energy levels to the CO 2 (001) level. Energy flow from the CO 2 (001) level at 2349 cm 1 to the CH 2 D 2 levels (at 2202 cm -1 ) and the CH 3 D level (at 2200 cm -1 ) should be considerably faster than to the lower lying CH 4 level at 1534 cm -1 . The two states in CH 2 D 2 can also accomodate more vibrational excitation than the single state in CH 3 D. This is reflected in the higher enrichment obtained in the CH 2 D 2 reaction.
The dramatic increase in the enrichment factor or as the wall emperature is decreased can be qualitatively attributed to two types of processes occurring in the reaction system. First, as the temperature is decreased, the thermal reaction, which is isotopically nonselective, is reduced, and the increase in the enrichment reflects mainly vibrational effects. Secondly, at higher temperatures, collisions could facilitate scrambling by the vibrational excitations in the two methanes through VV and VT processes involving the larger amount of CO 2 present.
The results of Example IV clearly demonstrate the applicability of the present technique over a wide range of feed ratio. This is aspect is important for commercial, large-scale applications of the present invention.
Obviously, many modifications and variations of the present invention was possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described. | Isotopes of hydrogen are separated by reacting a normal alkane, its deuterated form, atomic bromine, a deactivating gas, and a isotopically selective vibrational sensitizer gas selected from the class consisting of carbon dioxide, carbon monoxide, nitrogen, and mixtures thereof and separating the products which are enriched in deuterium. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This co-pending application has subject matter related to application Ser. No. 463,681, filed Apr. 24, 1974, said application being located in Group 147, said application being commonly owned with the present application.
BACKGROUND OF THE INVENTION
The present invention relates to a process and apparatus for producing embossed thermoplastic sheet material utilizing a vacuum embossing method and apparatus with an endless, seamless screen as the embossing surface, the screen being supported by two support rolls, a drive roll, and two seal rolls.
Embossed plastic film or sheet material has come into widespread use in many fields. One particularly large scale use of embossed thermoplastic sheet material is that of disposable articles such as hospital pads and drapes, wearing apparel and disposable diapers. Embossed film is also finding increased use in the packaging field, for example, as bags and overwraps for articles such as clothing and for shopping bags. In order to fulfill the requirements established by the end use of embossed film, it is desirable that the film have suitable properties for handling by fabricating machines, particularly those used for the manufacture of disposable articles, e.g., disposable diapers, sheets, pillow cases, drapes, raincoats, etc. In many cases it is important that the embossed thermoplastic film be soft and flexible and have the proper pattern and embossed depth in order to provide the desired "hand" or clothlike feel for the thermoplastic embossed material. Additionally, for many uses it is desired that the embossed thermoplastic material have as low a surface gloss as possible in order to simulate woven clothlike fabrics. Further, embossed thermoplastic materials must meet minimum physical specifications which are necessary in order that the films be handled in high speed, automatic fabricating machines, i.e., they should have suitable modulus, tensile strength, and impact strength.
Heretofore, embossed thermoplastic films such as polyethylene, polypropylene, polybutene-1, polyvinyl chloride and other flexible thermoplastic thin films have been made by various methods. One method is to extrude the thermoplastic film from a conventional slot die onto a continuously moving, smooth, cool, casting surface, e.g., a chill roll. The engraved pattern may be applied to the chill roll and the film pressed to the roll while in the amorphous or molten stage by press rolls. Alternatively, the chill roll may be smooth and the desired pattern in the film may be pressed into the film on the chill roll by means of an engraved and machined embossing roll which is pressed against the film and the chill roll to impress the pattern into the film as it is cooled on the chill roll.
Another technique used is to produce engraved rollers and to provide a heated, moving strip of film for engagement by the nip of the rollers, one of which carries the embossing pattern.
Embossed film has been prepared to a very limited extent by the use of vacuum embossing processes. Heretofore, it has been difficult to economically produce vacuum embossed film which has the characteristics and properties of film produced by the more conventional high pressure embossing processes. In one process for producing vacuum embossed film an endless belt made of a wire mesh which is butt welded to produce the endless belt is utilized. One embodiment is carried over a vacuum box, and heated film is applied thereto to impress the pattern of the screen on the heated film. In another embodiment the endless, butt welded screen is mounted on a cylindrical drum having a foraminous surface, and vacuum is applied to the hollow drum to pull the heated film into contact with the wire screen. However the belts have a welded joint mark which marks the embossed film once during each revolution of the belt. Thus, the film is suitable only for use in limited applications wherein the pattern can be cut into sections and used to avoid the joint mark produced by brazing or welding the ends of the metal screen together.
Other processes used in vacuum embossing film utilize perforated vacuum embossing cylinders which carry an outer layer of a porous substance, such as metallic mesh, fiberglass, embossed paper, or woven fabric materials, as the outer embossing surface thereon. The perforated cylinders carry on their outer surface the sized sleeve which is either butt jointed and/or lap jointed and thus produces a transverse mark on the thermoplastic embossed film as it is carried over the joint in the sleeve covering. It has been suggested to reweave the fabric together; however, it has been found that this is an extremely tedious and expensive operation and cannot be commercially accomplished to produce a wide variety of rolls from fabric materials.
From the foregoing, it can be seen that the previously utilized processes and apparatuses for vacuum embossing film suffer from numerous disadvantages which either increase the cost of vacuum embossed film and/or produce vacuum embossed film which does not have properties equivalent to that of film embossed by the pressure embossing method. Previously used processes and apparatuses for vacuum embossing film have suffered from the inability to produce long, continuous lengths of vacuum embossed film without having transverse marks across the film at periodic intervals equal to the length of the embossing belt and/or the circumference of the screens which are used to cover the embossing cylinder.
Additionally, many of the processes and apparatuses used heretofore for vacuum embossing film do not produce clear, distinct, sharp patterns having the desired "hand" or feel which is comparable to pressure embossed film. Further, many of the films produced by vacuum embossing have been found to be very deficient in physical properties to equivalent embossed films, i.e., they have a low modulus, low tear strength, poor impact strength and nonuniform roll contours when rolled into large size rolls for shipment.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a process and apparatus for producing vacuum embossed thermoplastic film.
It is a further object of the present invention to provide a process and apparatus for producing vacuum embossed thermoplastic film having enhanced physical properties.
It is a still further object of the present invention to provide an economical and efficient apparatus for producing said film.
The process of the present invention for vacuum embossing thermoplastic film may be carried out by continuously advancing a length of the film that is heated at least to its softening temperature and applying the heated film to a portion of the surface of an endless, seamless, perforated screen or belt supported on a plurality of rotatable rolls. The perforated screen or belt is advanced at the same rate as the heated film. A vacuum is applied to at least a part of the undersurface of the perforated screen or belt to pull the heated film into contact with the top surface of the screen or belt to cause the film to assume the shape of the pattern provided on the top surface of the screen or belt. Heat is removed from the embossed film at a rate sufficient to maintain the embossed film at a temperature sufficiently low enough to cause the embossed film to substantially retain the pattern when removed from the belt or screen. The film is continuously removed from the screen or belt.
The apparatus of the present invention for vacuum embossing sheet material includes a pair of spaced apart support rolls, a drive roll positioned intermediate and to one side of the pair of support rolls, a support structure for mounting the pair of support rolls and the drive roll for rotation, an endless, seamless, flexible, porous screen mounted on the pair of support rolls and the drive roll for rotation therewith, and a vacuum assembly positioned between the pair of support rolls and engaging a portion of the underside of the screen that extends between the pair of support rolls.
The product aspects of the present invention are realized in a vacuum embossed thermoplastic film having the following physical properties:
Tensile Strength Machine Direction 3,000 psi Transverse Direction 1,600 psiElongation Machine Direction 275 percent Transverse Direction 400 percentModulus at 1% Machine Direction 15,000 psi Transverse Direction 12,000 psiImpact (26 in Dart Drop) 90 gramsStress at 25% 600 gramsCoefficient of Friction 1.0Gloss at 45 degrees 9Embossed Thickness 3.5 milsUnembossed Thickness 0.9 milDensity 0.96 g/cc
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective, schematic view of one embodiment of an apparatus of the present invention suitable for carrying out the process of the present invention;
FIG. 2 is a perspective, schematic view of a second embodiment of an apparatus of the present invention suitable for carrying out the process of the present invention;
FIG. 3 is a top plan view of a portion of a preferred embodiment of the apparatus of the present invention with a portion of the endless, seamless screen being cut away;
FIG. 4 is a partial elevational sectional view taken along lines 4--4 of FIG. 3;
FIG. 5 is a cross-sectional view taken along lines 5--5 of FIG. 3;
FIG. 6 is an end view of a portion of the apparatus of Figure 3; and
FIG. 7 is a detailed view of a spring tensioning portion of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is shown a schematic view of an apparatus of the present invention suitable for carrying out the process of the present invention which includes a conventional slot die 10. It will be understood that slot die 10 is fed a plasticized melt of a suitable polymer for forming a film (e.g., polyethylene, polypropylene, polyvinyl chloride) and extrudes a sheet of film 11 in a downward direction. The sheet of film 11, while still hot from extrusion, is applied to the top surface of an endless, seamless, flexible, porous screen 22 by means of a heated lay-on or lag roller 12. Screen 22 is mounted on drive roller 14 and on support rollers 15 and 16. Spaced apart cylindrical seal rolls 17--17 make rolling contact with the underside of screen 22. A vacuum is applied by manifold 25 to the area lying between support rolls 17--17 and seal roll support member 18 to pull the film 11 down onto screen 22 to emboss the film. After the film leaves screen 22 it next passes over chill roller 13 which is temperature-controlled to cool the film, and from there it passes on to any suitable wind-up apparatus (not shown) or the like for storing the film. Rolls 12, 13, 14, 15 and 16 are hollow inside and have hollow shafts 12a, 13a, 14a, 15a, and 16a, respectively, at each end thereof for circulating heating or cooling fluid therethrough.
Referring now to FIG. 2, there is shown a second embodiment of an apparatus of the present invention for carrying out the process of the present invention. The apparatus shown in FIG. 2 is substantially the same as that described hereinbefore in connection with FIG. 1 and the same reference numerals are used to identify the same components. In this embodiment, the film is a preformed film which is passed downward in close proximity to heater 20 which raises the temperature of the thermoplastic film 11 to a softened state for embossing. In the embodiment shown in FIG. 2, heater 20 may be an electrical resistance heater which is used to heat the film. It is understood that any other suitable means may be used for heating the film, e.g., infrared lamps, hot air, passing the film over heated rollers, or in contact with other suitable heated surfaces. The heated film is then received in the same apparatus as described hereinbefore in FIG. 1 to produce an embossed pattern thereon.
FIGS. 3-7 depict in greater detail a preferred embodiment of an apparatus of the present invention for vacuum embossing film. Referring now to FIGS. 3, 4, and 5, the apparatus includes a generally hollow, cylindrical drive roll 14 which drives screen 22 about support rolls 15 and 16 and over seal rolls 17--17. Rolls 14, 15, and 16 can be made from any suitable metal, e.g., steel, aluminum, bronze, etc. Drive roll 14 is preferably covered with a suitable elastomeric covering 14b such as, for example, a neoprene or silicone rubber. As seen in FIG. 4, drive roll 14 is rotatably supported by hollow shaft members 28--28 received in bearings 19--19, which are attached to end plates 34--34. Shaft members 28--28 are connected by hollow nipples 29--29 and lock nuts 42--42 to rotating unions 36--36. One of the unions 36 is connected by a supply conduit (not shown) to a suitable supply of a heating or cooling fluid, e.g., water or oil, and the other union is connected to a discharge conduit (not shown) for returning the fluid to the supply source. Thus a heating or cooling fluid may flow through the hollow interior 14c of drive roll 14, as indicated by the arrows in FIG. 4.
Support rolls 15 and 16 are similar in construction to drive roll 14 and are supported by hollow shaft members 15b-15c and 16b-16c, respectively, which are received in bearings 19a--19a and 19b--19b attached to end plates 34--34. Also, support rolls 15 and 16 are hollow inside and are constructed in such a manner that heating or coolant fluids such as oil or water may be forced therethrough in the manner indicated by the arrows in FIG. 3. As can be seen in FIG. 3, support rolls 15 and 16 may be heated or cooled by supplying a fluid through hollow shaft members 15c and 16c at one end and discharging the fluid through hollow shaft members 15b and 16b at the other end. Support roll 15 is biased away from drive roll 14 and support roll 16 by springs 40, as can be seen in FIGS. 5, 6, and 7. The springs 40 are contained within slots 40a in end plate 34. The springs 40 urge bearing assembly 19a outwardly to force support roll 15 to place tension upon screen 22 to force screen 22 snugly against the support rolls 15 and 16 and drive roll 14. As can be seen in detail in FIG. 7, each spring 40 applies force against a bolt 44 which has nuts 42 and washer 43 connected thereto to slideably couple the bearings 19a--19a to the end plates 34--34.
A vacuum assembly, designated generally by the numeral 23 is positioned between support rolls 15 and 16 and directly above drive roll 14 to apply vacuum to a portion of the underside of the top of screen 22. The assembly includes a generally rectangular bottom support plate 18 which extends between end plates 34--34 and is attached thereto by welding or other suitable means. A seal retainer strip 24 is attached by bolts or other suitable means to each side edge of bottom support plate 18 and projects upwardly therefrom. A pair of spaced apart seal rolls 17--17 are slidingly supported by bottom plate 18 and make a sliding seal with retainer strips 24--24. Seal rolls 17--17 are preferably made from Teflon or other suitable plastic materials having a low coefficient of friction. Located between seal rolls 17--17 are deckles 30--30 which in turn are threadably connected to deckle screws 31--31. Deckle screws 31--31 are connected by collars 21--21 to end plates 34--34. By turning deckle screws 31--31, deckles 30--30 can be made to move inwardly and outwardly along the shaft of the screw to adjust for various widths of screen 22. Each deckle 30, as can be seen in FIG. 5, has parallel top and bottom edges which make sliding contact with the underside of screen 22 and support plate 18 respectively. The side edges of each deckle are generally semi-circular in shape and fit flush against seal rolls 17--17 to provide a sliding vacuum seal therebetween. Located immediately below bottom support plate 18 is vacuum manifold pipe 25 which projects through end plates 34--34 and is attached thereto by welding or other suitable means. As can be seen in FIG. 4, manifold pipe 25 is connected to openings 27--27 in support plate 18 by inlet conduits 26--26 through which air flows in the direction indicated by the arrows when a vacuum is applied to manifold pipe 25. Vacuum is thus applied to the underside of screen 22 which overlies the vacuum chamber 50 defined by seal rolls 17--17, deckles 30--30 and bottom support plate 18. When heated film 11 is carried by screen 22 over seal rolls 17--17, the vacuum or low pressure existing in chamber 50 pulls the heated film 11 tightly against screen 22 to emboss the film.
To carry out the process of the present invention a sheet of heated thermoplastic film 11 is applied to the top surface of screen 22 lying between support rollers 15 and 16. Screen 22 is rotated by drive roll 14 thereby pulling film 11 over vacuum chamber 50. Vacuum is applied to each end of the vacuum manifold pipe 25 and thus creates a vacuum within the chamber 50 pulling the heated film into firm embossing contact with the upper surface of the embossing screen 22 to thereby transfer the pattern of the embossing screen to the heated film 11. The heated film 11, after passing over the vacuum space 50 is carried by screen 22 and around chill roll 13 where the embossed film is rapidly cooled to set the pattern of the film and then the cooled film is removed and wound on a storage roll or other suitable storage means (not shown). The heated film 11 may be supplied by any of the means described hereinbefore, i.e., by extrusion from a slot die mounted directly above the embossing apparatus or by passing the film through a heated air oven, or by heating the film by noncontacting or contacting means, i.e., infrared heaters or heated rollers. The film, after passing over vacuum chamber 50 may also be cooled by circulating a cooling medium, e.g., refrigerated water, through hollow support roll 15. Optionally, the embossed film may also be cooled by applying cold air to the top surface of the film after it passes over the vacuum chamber. Additionally, the heated film 11 may be further heated before being applied to the screen 22 by circulating a heating medium, e.g., hot oil, through a lag or lay-on roll 13, as seen in FIGS. 1 and 2. Screen 22 may be preheated to enchance embossing of heated film 11 by circulating a heating medium through hollow drive roll 14. Also, an auxiliary heater roll (not shown) may be positioned between drive roll 14 and support roll 15 in rolling contact with screen 22 to add heat to the screen 22.
Suitable thermoplastic materials may be embossed by the process of the present invention, i.e., thin webs of from 0.25 mils up to as thick as 10 mils. Exemplary thermoplastic materials uitable for vacuum forming according to the present invention are polyethylene and polyethylene copolymers, e.g., polyethylene-polypropylene copolymers; polyvinyl chloride polymers and copolymers, e.g., polyvinyl chloride-polyvinyl acetate copolymers; polypropylene homopolymers and copolymers; Saran films; Mylar films; polystyrene films, and others.
Embossed film was produced utilizing the process and apparatus of the present invention. A polyethylene resin, No. 5561, manufactured by Gulf Oil Corporation was extruded on a Davis-Standard extruder with 21/2 inch screw into an Egan slot die having a die gap of 0.025 inch and a width of approximately 16 inches. The support and drive rolls carried an electroformed, endless, seamless, nickel, embossing screen having hexagonal openings. The screen had 28 openings per linear inch (784 openings/square inch). The screen was cooled by blowing refrigerated air on it and contacting the screen with the water-cooled drive and support rolls. Two inches of mercury vacuum was applied to the underside of the seamless embossing screen using a rotating vane vacuum pump driven by a 71/2 horsepower motor. The vacuum embossed film was rolled up, and samples were tested for physical properties. Samples of the embossed film were found to have the following typical physical properties:
Tensile Strength Machine Direction 3,000 psi Transverse Direction 1,600 psiElongation Machine Direction 275 percent Transverse Direction 400 percentModulus at 1% Machine Direction 15,000 psi Transverse Direction 12,000 psiImpact (26 in Dart Drop) 90 gramsStress at 25% 600 gramsCoefficient of Friction 1.0Gloss at 45 degrees 9Embossed Thickness 3.5 milsUnembossed Thickness 0.9 milDensity 0.96 g/cc
While the use of refrigerated air and water contact have been described as one form of cooling the embossing roll or screen, it is understood that other forms may be used, i.e., internal fluid cooling may be utilized by providing suitable conduits and passages on the inside of the embossing roll. Also, conduits and passages can be provided in both the drive roll 14, support rolls 15 and 16, and chill roll 13 to remove heat from the embossing screen 22.
The physical properties of the samples of embossed film set forth hereinbefore utilized the following test methods: Tensile Strength, ASTM D882-67, Method A; Elongation, ASTM D882-67, Method A; Modulus at 1%, ASTM D882-67, Method A; Impact Strength, Drop Dart using ASTM D1709-67; Density, ASTM D1505-68; Gloss, ASTM D457-65T; Coefficient of Friction, ASTM D1894-63; and Stress (= Tensile at 25% elongation), ASTM D882-67, Method A.
The foregoing embodiments are exemplary of the process and apparatus for carrying out the present invention; however, many variations of the invention may be made without departing from the spirit and scope of the invention. | A method and apparatus for vacuum embossing sheet thermoplastic material which utilizes an endless, seamless structure as the embossing surface. A sheet of heat-softened thermoplastic film is passed over an embossing screen, the embossing screen being supported by two support rolls, a drive roll and two seal rolls. A vacuum is applied to the screen between the seal rolls to pull the film into contact with the screen thereby producing an embossed pattern on the film corresponding to the outer surface of the screen. After the film is removed from the endless, seamless screen the film is cooled to set the pattern in the film. The process produces an embossed film which has high strength, low surface gloss or light reflectance, and a deep embossed pattern. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of U.S. provisional patent application Ser. No. 60/568,443, filed on May 4, 2004. The above referenced application is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a drug delivery device. In particular, the present invention provides a portable, compact drug delivery device.
[0003] As medical knowledge increases, more and more drugs are created to treat a variety of diseases, illnesses and other medical conditions. Many of these drugs need to be taken at specific times or time intervals. It may be inconvenient for people to arrange to go to where their medicines are stored at each time a dose of medicine is needed. It also may be inconvenient for people to carry standard size forms of the medicine around with them, as they can be bulky. Standard size forms of medications include designs such as tablets, capsules, caplets and pills, for example.
[0004] Some medicines need to be taken upon the occurrence of a specific situation, such as exposure to an allergen. Common situations where medicine may need to be taken spontaneously include emergency situations such as, for example, heart attacks, strokes, asthma, anxiety (panic) attacks and pain related to illness.
[0005] A blockage of blood to the heart may cause a heart attack, also known as a myocardial infarction. If the supply of blood, which carries oxygen to the heart, stops, affected portions of the heart muscle may die. This condition may cause the heart to stop pumping or for the pumping function to be impaired. Blockages may be caused by the formation of plaque, or arteriosclerosis, in blood vessels. If sections of plaque are dislodged from the walls of the blood vessels a clot may be formed.
[0006] Although the precise reasons for its effects are not fully understood, it is believed that taking aspirin (acetylsalicylic acid) at the first signs of a heart attack may reduce the severity of such a condition. The United States Food and Drug Administration and medical research have reported that use of aspirin has been indicated as reducing the risk of death from a heart attack or damage to the heart from a heart attack. However, to be most effective, aspirin must be taken at the first signs of a heart attack.
[0007] Accordingly, a need exists for a portable, convenient and secure package or delivery device for providing easily accessible dosages of drugs, such as aspirin. The conditions for which one would use such delivery devices are situations where rapid delivery of the drug is essential. For example, it is known that crushing a drug may lead to more rapid absorption of the drug by a person.
[0008] U.S. Pat. No. 6,516,950 to Robertson purports to suggest a credit card-sized carrier for a medicament. Robertson appears to provide a carrier for transporting a medicament wafer. When a dose of medication is needed, one can presumably open the carrier, remove, and ingest all or a part of the medicament wafer located inside the carrier. However, Robertson suffers from several disadvantages. First, Robertson apparently utilizes a very small container that holds a medicament wafer. Robertson contains very little discussion of how such a container might be constructed and it appears that it may be difficult and expensive to manufacture carriers of the type envisioned by Robertson. Second, the small size of the Robertson container likely would make the container difficult to open in an emergency situation. A more readily accessible form of the drug will save valuable time. Third, the small size of the container dictates that an even smaller medicament wafer must be used inside the Robertson container. It does not appear that Robertson contains any disclosure of how such thin wafers of drugs, including aspirin, may be produced. Furthermore, thin wafers of the drug may be difficult for a person to remove from the container and manipulate. The thin wafer may be brittle and break with handling. Finally, it is not clear that Robertson truly contemplates a credit card-sized drug delivery device. Robertson appears to suggest that drug delivery devices that are larger than credit cards may be used and still fit in a wallet, or otherwise be suitably transportable.
[0009] An unmet need in the art exists for a portable, easily carried drug delivery device that is easily accessed and manipulated so that a dosage of a drug may be administered as quickly as possible. It would also be beneficial for such a drug delivery device to be easily and cost effectively manufactured.
BRIEF SUMMARY OF THE INVENTION
[0010] In one embodiment, the present invention is directed to a drug delivery device comprising an edible material about the size and shape of a pocket card, that is, a pocket-sized card. A drug is dispersed within the edible material. The drug delivery device may be conveniently carried by a person, allowing easy access to the drug. The person may administer a dosage of the drug by ingesting all or part of the drug delivery device. For example, chewing and crushing the dosage produces saliva to further enhance delivery of the drug.
[0011] The edible material of the drug delivery device may include a bottom layer having a first thickness and at least one cavity formed in the bottom layer where the cavity has a second thickness, the second thickness being less than the first thickness. The edible material of the drug delivery device may further include a top layer having a first thickness with the top layer being substantially congruent with the bottom layer. In one embodiment, at least a portion of the drug is disposed in the cavity.
[0012] In another embodiment, the present invention provides a method for delivering a drug to a person involving (a) providing a drug delivery device to be carried by a person, wherein the drug delivery device comprises an edible material substantially of the size and shape of a pocket card, and wherein the drug is dispersed within the edible material; and (b) allowing a dosage of the drug to be administered to the person by ingestion of all or a part of the drug delivery device. In a further embodiment, the present invention involves administering the dosage of the drug in response to a physical symptom corresponding to one or more emergency situations selected from the group consisting of angina, heart attack, stroke, asthma, anxiety attacks and pain related to illness. Aspirin (based on acetylsalicylic acid) may be used to alleviate heart attack symptoms, for example.
[0013] In yet another embodiment, the present invention may involve administering the dosage of the drug to the person in response to a physical symptom corresponding to one or more emergency allergic situations selected from the group consisting of insect bite (such as bee stings) hypersensitivity and food (such as peanuts) hypersensitivity. Antihistamines may by used to alleviate certain allergic reactions.
[0014] The various embodiments of the present invention may, but do not necessarily, achieve one or more of the following advantages:
the ability to quickly administer a drug; provide a portable drug delivery device that may be carried in a purse, wallet or pocket; provide a drug delivery device that is ingestible; provide a drug delivery device that is palatable, that is, having a pleasing taste; provide a drug delivery device that is sturdy and may withstand handling and manipulation; provide a drug delivery device of which a portion may be removed and ingested in order to provide a desired drug dosage; and provide a drug delivery device that is easily and cost-effectively manufactured.
[0022] These and other advantages may be realized by reference to the remaining portions of the specification, claims and abstract.
[0023] The above description sets forth, rather broadly, a summary of one embodiment of the present invention so that the detailed description that follows may be better understood and contributions of the present invention to the art may be better appreciated. Some of the embodiments of the present invention may not include all of the features or characteristics listed in the above summary. There are, of course, additional features of the invention that will be described below and will form the subject matter of claims. In this respect, before explaining at least one preferred embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and to the arrangement of the components set forth in the following description or as 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is substantially a perspective view of one embodiment of a drug delivery device according to the present invention.
[0025] FIG. 2 is substantially a perspective view of one embodiment of a drug delivery device according to the present invention.
[0026] FIG. 3 is substantially a top view of one embodiment of a spacer for use in creating at least one embodiment of a drug delivery device according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] In the following detailed description of certain embodiments of the present invention, reference is made to the accompanying drawings, which form a part of this application. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
[0028] For the purposes of the present invention, it is understood that “pocket card” or “pocket-sized card” includes cards having shapes and sizes suitable for being carried in purses, wallets or pockets, including, for example, those in the form of cash or credit cards.
[0029] With reference to FIG. 1 , the present invention is directed to a drug delivery device 104 . In certain embodiments, drug delivery device 104 may be contained in a protective packaging 106 , such as foil or plastic wrapping, for example. The protective packaging may serve to protect drug delivery device 104 from harmful environmental conditions such as humidity, water, heat and light; and also to draw attention to the drug delivery device via printed symbols or other information.
[0030] Drug delivery device 104 may comprise one or a plurality of dosages. If drug delivery device 104 contains multiple doses, drug delivery device 104 may be divided into a plurality of segments 110 , each segment 110 may correspond to one dose or part of a dose. Segments 110 may be designed to easily be separated from the remainder of delivery device 104 . For example, drug delivery device 104 may be provided with perforations 114 . In the case where aspirin is the drug, a typical dosage may correspond to about 325 milligrams (mg) of aspirin. For example, if drug delivery device 104 were made up of four segments 110 , then each of the segments may contain approximately 325 mg of aspirin, providing four separate doses that could be taken by a person in the time of need. Alternatively, the entire drug delivery device 104 may contain about 325 mg of aspirin, in which case the person would ingest the entire card to receive this dosage of aspirin.
[0031] Drug delivery device 104 may be of any suitable shape and dimension corresponding to that of a pocket card. A pocket card-sized drug delivery device may be advantageous as being both large enough to be sturdy and withstand handling, yet small enough to be easily transported, such as being placed in a purse, wallet or pocket. The pocket card-sized drug delivery device may be in the form of a cash or credit card; credit cards typically are dimensioned with a length of about 3.5 inches (8.9 centimeters (cm)), a width of about 2.25 inches (5.7 cm), and a thickness of about 0.05 inches (1.3 millimeters (mm)). However, pocket card-sized delivery devices of the present invention may range from about 2 to 10 cm in length, from about 1.2 to 6.5 cm in width, and from about 0.5 to 5 mm in thickness; more typically, from about 5 to 9 cm in length, from about 3 to 6 cm in width, and from about 0.7 to 2 mm in thickness;
[0032] In other embodiments, drug delivery device 104 , may be smaller than a traditional credit card. For example, if each drug delivery device 104 only contains one dose of a drug, the dimensions of drug delivery device 104 may be reduced to make the drug dosage more easily ingestible. For example, drug delivery device 104 may have a similar thickness as a credit card, but be about 75% smaller in length and width, that is, about 2.2 cm by 1.4 cm in length/width, respectively. A drug delivery device 104 with these dimensions may still be easily transported, such as in a wallet or pocket, yet may constitute less material to be ingested at once. Also, this embodiment results in less wasted drug.
[0033] In other embodiments, such as shown in FIG. 2 , a drug delivery device 104 may comprise a drug-containing portion 206 and an inert material 212 . Drug containing portion 206 may be removably attached to inert material 212 . The combined size of drug-containing portion 206 and inert material 212 may be approximately the size of a standard credit card, as described above. In this embodiment, drug delivery device 104 retains a convenient pocket-card size, but a smaller portion may be ingested to provide a drug dosage.
[0034] Drug delivery device 104 may be formed from one or more edible materials containing the desired drug dosage. The edible material may be easily ingested, broken down by the body, and may be stable for prolonged periods of time in order to give drug delivery device 104 a reasonable shelf life. Suitable edible materials include, without limitation, starches and edible, biodegradable polymers, such as polycaprolactone (PCL), polymers based on lactic acid (PLA), glycolic acid and combinations thereof (PLGA), for example. Depending on the material used for drug delivery device 104 , the drug itself may be dissolved in the edible material, mixed with the edible material, or placed between layers of one or more edible materials. Suitable drug delivery devices 104 may be produced by sandwiching the desired drug, such as aspirin, between two layers of starch or edible polymer.
[0035] Although many edible materials may be used for drug delivery device 104 , starch has many properties characteristic of a suitable edible material. Starch is edible and fairly inert, and therefore unlikely to adversely react with many drugs. Starch is sufficiently sturdy to withstand handling, yet is also flexible and can be made soft enough to chew. The physical and aesthetic properties of a drug delivery device 104 using starch, such as the flexibility, chewability and taste, may be altered by adding other ingredients such as cellulosics, modified starches, glycerin and sugars, for example. It is understood that other optional inactive ingredients also may be included in formulating drug delivery devices of the present invention, such as, for example, croscarmellose sodium, calcium phosphate, magnesium stearate, microcrystalline cellulose and sodium bicarbonate.
[0036] Starch is also fairly resistant to water and humidity. Water-resistant coatings may be applied to the starch-based drug delivery device 104 to further protect the drug from moisture. Although starch is not particularly light sensitive, pigment may be added to the starch to make the card opaque, and thereby help protect any light sensitive drugs that might be placed inside drug delivery device 104 .
[0037] The drug may be incorporated into drug delivery device 104 in a number of ways. For example, the drug may be dispersed in the edible polymer and the card formed from the dispersion. In other embodiments, drug delivery device 104 may comprise layers of edible material that form a cavity. The drug may then be placed in the cavity. Placing the drug in the cavity may be beneficial when it is desired to have faster release of the drug. Time-release of the drug may be obtained by altering the properties of the polymer, such as by using various crosslinking agents.
EXPERIMENTAL
[0038] The following methods provide non-limiting examples of certain embodiments of drug delivery device 104 and their preparation.
Example I
Starch-Based Drug Delivery Devices
[0039] A top layer was prepared by mixing 5 grams (g) of starch, 2 g of table sugar and 2 grams of glycerin with water to a total volume of 50 milliliters (ml). The mixture was heated on a hot plate at about 100° C. and stirred using manual stirring until a viscous and translucent gel formed, about 10-15 minutes. The resulting gel was poured into a 5.5 inch (14 cm) diameter dish coated with poly(dimethyl siloxane) (PDMS), which is used to help prevent the gel from sticking to the dish; fluorocarbon coatings, such as Teflon™ polymer could also be used. The gel was then dried at room temperature for 48 hours. If desired, the dish may be placed in a vacuum chamber in order remove bubbles from the gel. The size and shape of the drug delivery device 104 produced by this method may be changed and controlled by altering the size and/or shape of the dish and by altering the amount of gel used.
[0040] A base layer was prepared by mixing 10 g of starch, 5 g of table sugar, 5 g of glycerin, and adding water to give a total volume of 100 ml. The sugar and glycerin are used to adjust the brittleness of the starch and the amount used can be adjusted to achieve the desired combination of flexibility, rigidity and chewability. The mixture was heated and stirred as before until a viscous and translucent gel formed. The gel was poured into a 5.5 inch (14 cm) diameter PDMS-coated dish with two glass slide pieces at the bottom. The gel was dried at room temperature for 48 hours and a film with two cavities was obtained. The gel can then be peeled off the dish and cut to the desired dimensions.
[0041] Starch powder was used to simulate a drug. The starch powder was placed in the cavities in the base layer. The top layer was placed over the base layer and pressure was applied by placing a hard board on top of the top layer and placing a weight on top of the hard board. Although many weights could be applied, a weight of about 20 to about 40 pounds (9 to 18 kg) may be used in order secure the top layer to the base layer. The sample was then cut to approximately the size of a credit card.
EXAMPLE II
Poly(Lactic Acid)-Based Drug Delivery Device
[0042] Poly(lactic acid) (PLA), a biodegradable polymer, was obtained from Alkermes, Inc. in different molecular weights. In this example, PLA having a molecular weight of about 45,000 was used. It is understood that those of skill in the art will recognize that the mechanical properties of drug delivery device 104 may be altered by altering the molecular weight of the polymer used.
[0043] Because pure PLA is rather brittle, the polymer was made more pliable by modifying the polymer with a surfactant. The polymer was modified with a surfactant, Pluronic™ F127 Prill (available from BASF Corp.), by mixing the surfactant with the PLA at a ratio of 5 weight percent (wt %) surfactant in PLA in a microcompounder. The major component of the surfactant is poly(ethylene oxide)/poly(propylene oxide)/poly(ethylene oxide) (PEO-PPO-PEO) tri-block copolymer. Other surfactants, such as poly(vinyl acetate), may be used.
[0044] A mixture of PDMS resin and a curing agent (SYLGARD™ 184 kit, available from Dow Corning) in a 10:1.05 wt/wt ratio was poured into an aluminum mold spacer attached to a glass plate. Various ratios of resin to curing agent can be used, such as in the range of about 10:1.0 to about 10:1.05. FIG. 3 shows one embodiment of a suitable spacer 300 is shown in FIG. 3 . The thickness of the spacer was approximately 0.6 mm. The spacer had four cavities 306 ; overall width and length dimensions of spacer 300 are indicated by A and B, respectively; width and length dimensions of the individual cavities are indicated by a and b, respectively; optional attachment of the card to a key-ring may be provided by a hole having a radius r. The spacer may be constructed from suitable materials such as metals and plastics. Aluminum is particularly easy to work with using conventional machining tools, such as a driller.
[0045] After the PDMS mixture was added to the mold, the mold was placed in a vacuum oven for several minutes in order to remove air bubbles formed during mixing and pouring. The PDMS mixture was then cured for two hours at 65° C. After curing, the cured PDMS mold spacer was peeled from the aluminum mold.
[0046] A PLA film with a thickness of about 1 mm was prepared via compression molding. Compression molding involves pressing a polymer melt into a mold and holding the polymer under pressure until the system cools down. The compression pressure is typically varied between 0.01 to 10 MPa (megapascals) depending on the nature the materials and the temperature. In the present method, the PLA film was placed on a pre-heated hot plate at 220° C. for 2 minutes. The PDMS mold spacer was then embossed onto the deformable PLA film and held under a pressure of about 0.5 MPa for 1 minute. The PDMS/PLA construct was then cooled to room temperature and the PDMS mold was peeled off of the PLA substrate.
[0047] Next, 0.70 g of aspirin was placed in the cavities of the PLA substrate, greater or lesser amounts of aspirin may be used. In certain embodiments, 1.0 g of aspirin may be added to the PLA substrate. A bonding solution was prepared by dissolving 1 g of PLA in 10 g of acetone to form a 10% solution by weight. The solution was used to bond the PLA substrate to a PLA cover to form a “card.” The PLA cover may be prepared by the same method as the cavities using a separate mold. The card was placed into a vacuum oven to remove the solvent.
Example III
[0048] If desired, dyes can be added to the drug delivery device. A sample was prepared according to the procedure described in EXAMPLE II. However, 2% of acid orange food dye (obtained from Sigma-Aldrich) was added to the PLA. In this instance, 0.50 g of aspirin (total) was loaded into the sample cavities. If desired, each cavity can be made separately detachable from drug delivery device 104 by scoring or perforating the area around each cavity. Such scoring may be incorporated into a mold or may the final drug delivery device 104 may be appropriately machined.
[0049] 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. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents rather than by the examples given. | A drug delivery device having the shape and size of a pocket card and including a drug dispersed in an edible material, is disclosed. The drug delivery device may be conveniently carried by a person, such as in the form of a cash or credit card, allowing easy access to the drug. The person may administer a dosage of the drug by ingesting all or part of the drug delivery device. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to decorations in general, and more particularly to an adorning article exhibiting a pom-pon appearance in its final state and intended to be attached to a gift package or the like for decorative purposes.
2. Description of the Related Art
There are already known various constructions of adorning articles of the type here under consideration, among them such that are being sold in its final, puffed-up state. Obviously, such articles occupy a considerable amount of space that is often at a premium, be it in storage, in transportation or on display. This problem has been recognized before, and a remedy was found in a ribbon having a drawstring loosely connected to it at spaced points along its length and secured to the ribbon at one end so that the user of the ribbon can draw the ribbon into a number of arcuate loops by pulling on the drawstring. An obvious advantage of this arrangement is that the ribbon can be packed flat, thus greatly facilitating and reducing the cost of storage and transport of the items as compared to those encountered with preformed bows that are relatively bulky and need to be packed in crush-proof containers.
Such prior art devices have, however, suffered from the disadvantage that, on pulling on the drawstring, the ribbon had tended to fold itself into loops aligned along a single vertical plane, thus forming a fan shape. This represents a pronounced inconvenience to the ultimate user who normally requires the bow to be arranged in a more decorative rosette or pom-pon form, and makes it necessary for the user to pull on the individual loops to displace them laterally in an effort to rearrange them so that they are spaced angularly around the axis of the bow. Apart from being time-consuming, this manipulation presents the risk of the bow becoming torn, damaged or soiled in the process.
This problem was addressed in U.S. Pat. No. 4,515,837 to Cheng, in that the ribbon arrangement provided therein includes two ribbons each including a plurality of consecutive segments connected to one another by respective narrow neck portions, the ribbons being connected to one another at the respective neck portions by respective retainer members which, due to the configurations of the neck portions, are caused to assume slightly inclined positions relative to the transverse width of the ribbons. With this ribbon arrangement, as the bow is being formed by pulling on the drawstring, each of the relatively stiff retainer members tends to seat itself on the bow loop that is being formed immediately adjacent thereto in an angularly skewed orientation relative to the latter, and thus imparts a bias tending to skew each loop of the bow relative to the previously formed loop, so that the loops are arranged in an angularly spaced rosette or pom-pon-like form.
As advantageous as this arrangement may be, experience with it has shown that it still leaves something to be desired as far as the appearance of the article in its final or finished form is concerned. More particularly, it was established that the top of the resulting article is somewhat relatively flat, that is, while there is obtained automatic distribution of the loops about the axis of the drawstring, no bias to speak of is applied to the loops to force the topmost ones of them to spread, against the force of gravity, into the empty space above them. This, of course, means that articles of this type are somewhat at a disadvantage as far as their appearance is concerned relative to the preformed pom-pon-like bows that are usually made much fuller on top.
OBJECTS OF THE INVENTION
Accordingly, it is a general object of the present invention to avoid the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide an adorning article in the form of a pom-pon that does not possess the drawbacks of the known articles of this type.
Still another object of the present invention is to devise an adorning article of the type here under consideration which has the look virtually indistinguishable from that of a professionally preformed article of this kind even though formed on site just prior to its use.
It is yet another object of the present invention to design the above adorning article in such a manner as to give it a much fuller, fluffier appearance than before in its finished form.
A concomitant object of the present invention is so to construct the adorning article of the above type as to be relatively simple in construction, inexpensive to manufacture, easy to use, and yet reliable in operation.
SUMMARY OF THE INVENTION
In keeping with the above objects and others which will become apparent hereafter, one feature of the present invention resides in an adorning article that includes as its components a pair of elongated ribbons. Each of these ribbons includes a stem portion and a branch portion merging with one another at a merger region. Each such ribbon is subdivided into a predetermined number of successive segments located both on the stem and branch portions thereof and interconnected with one another by respective intervening neck portions formed, in each instance, by a pair of incisions extending from respective edges of the respective one of the ribbons within the stem and branch portions and at the merger region toward each other but terminating short of meeting each other to define the respective one of the neck portions. At least one of the segments of each of the branch portions is folded back into juxtaposition with an adjacent segment of the same branch portion.
The article further includes means for connecting the ribbons to one another at each of the neck portions located on the stem portion between the successive segments and at the merger region, and the at least one folded-back segment of each of the branch portions to that of the neck portions that connects the adjacent segment with the next one, and a pair of drawstrings sandwiched between the stem portions of the ribbons, passing jointly through the neck portions of the stem portion and of the merger region and individually through the neck portions of the branch portions and between the folded-over and adjacent segments, with freedom of longitudinal movement, and each separately secured to a fold region present between the folded-over and adjacent segments. A particular advantage of this arrangement is that the ribbon material of the branch portions tends to fluff up, due to the interaction between the branch portions during the bow formation process, to a much greater extent than what could be attributed merely to the presence of additional ribbon material at the affected location.
Advantageously, each of the branch portions includes at least one segment situated next to the merger region that has no other of the segments of the same branch associated with it, so that it constitutes a weakened region at which deformation of the segments into loops preferentially commences in response to pulling on the drawstrings. It is also advantageous when the connecting means includes a multitude of individual retainer members, at least those of which that are disposed on the stem portions of the ribbons being inclined at predetermined angles with respect to the transverse width of the ribbons.
The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an adorning article according to the present invention in its initial, bow precursor, state;
FIG. 2 is a cross-sectional view, on a somewhat enlarged scale, taken on line 2--2 through the article of FIG. 1;
FIG. 3 is a view akin to that of FIG. 1 but taken during an initial stage of conversion of the precursor into a bow; and
FIG. 4 is another view similar to that of FIG. 1 but this time taken after the completion of the conversion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing in detail, and first to FIG. 1 thereof, it may be seen that the reference numeral 10 has been used therein to identify an article embodying the present invention, in its entirety. Inasmuch as the ultimate utility of the article 10 is to adorn a gift-containing package or for other decorative purposes, it will be referred to herein generally as an adorning article even when not yet deserving that designation because of not having attained its final decorative shape yet.
In accordance with the present invention, the article 10 includes as one of its main components a ribbon arrangement 11. The ribbon arrangement 11 includes a pair of generally ribbon-shaped main sections or members 11a and 11b disposed in face-to-face relationship. The members or ribbons 11a and 11b are advantageously formed by taking a length of ordinary but decorative (colored and/or patterned) ribbon material, e.g. any suitable commercially available synthetic plastic material having a satin-like fibrous texture, cutting it in half, and then juxtaposing the thus obtained discrete ribbons 11 and 12 in aligned relationship with one another, as may be discerned particularly from a comparison of FIG. 1 with FIG. 2 of the drawing.
As shown particularly in FIG. 1, the ribbon arrangement 11 is bifurcated, that is it includes a pair of auxiliary portions or branches denoted by the reference numerals 12a and 12b, respectively, that merge with each other to form a main portion or stem 12c. It will be appreciated that the article 10 can be stored indefinitely in its substantially flat original state (not shown) in which the branches 12a and 12b lie substantially flat against one another, forming respective continuations of the stem 12c that extend along a common plane with the stem 12c, albeit possibly with the article 10 being folded one or more times upon itself. However, as will become clearer later, the article 10 can be easily and quickly converted, when the need for it arises, from this original state through its initial and partially deformed precursor states illustrated in FIGS. 1 and 3, respectively, to its final bow state visible in FIG. 4.
The article 10 further includes an operating drawstring arrangement 13. As shown, and as currently preferred, the drawstring arrangement 10 includes a pair or individual drawstrings 13a and 13b; however, it is also possible and contemplated by the present invention for the two drawstrings 13a and 13b to be of one piece with one another, being folded at their lower ends, or connected to each other in some other fashion, such as by a knot, at a region situated below the ribbon arrangement 11, both as considered in FIG. 1. Such a connection would help in insuring identical or commensurate movement of the drawstrings 13a and 13b when pulled on; on the other hand, it would render manipulation with the strings 13a and 13b following such movement difficult and in many instances require severance of or a similar breakage or discontinuance of such connection or bond prior to such manipulation. In the final analysis, the decision on whether or not to have the strings 13a and 13b joined will be made based on a plurality of factors including those mentioned above. The drawstring arrangement 13, or each of its constituent parts 13a and 13b, may be made of the same material as the ribbon arrangement 11 but of a much narrower width at least in its final form.
The drawstrings 13a and 13b are connected to the ribbons 11a and 11b, respectively, in a manner and at locations yet to be described; however, before addressing that issue, the ribbons 11a and 11b, their configuration and function, and the way they are connected, will be discussed in some detail. As best seen in FIG. 1, each ribbon 11a and 11b includes a series of respective segments 15a.1 to 15a.n or 15b.1 to 15b.n, wherein n is any chosen integer (in the illustrated embodiment, seven) within reason. The segments 15a.1 to 15b.n are obtained in the ribbons 11a and 11b, which were substantially equally wide throughout to begin with, by forming respective substantially V-shaped indentations or incisions 16 and 17 that are cut or otherwise made on the opposite sides of the ribbon members 11a and 11b.
It may be seen that the segment 15a.1 is folded back along a folding line or crease 14a to become juxtaposed with the segment 15a.2; the same is true with respect to the segment 15b.1 vis-a-vis the segment 15b.2. Moreover, even though that is not shown in the drawing, there could be provided two or more other segments (which could be referred to as segments 15a.0 and 15b.0 for the sake of consistency, even though they are not shown in the drawing) that would then be juxtaposed with the segments 15a.2 and 15b.2, respectively, etc. The "folded-back" segment or segments can be of one-piece with the main ribbon sections 11a and 11b, or they can be discrete auxiliary ribbon sections.
Advantageously, all of the segments 15a.1 to 15b.n have substantially equal lengths, but that is not critical. As a matter of fact, in some cases it may be even preferred to make them of unequal lengths; even in that case, though, the associated ones of the segments 15a.1 to 15b.n, that is those that are directly juxtaposed with one another (such as, for example, 15a.4 and 15b.4 or, for that matter, 15a.1 and 15a.2) do have substantially equal lengths.
For the sake of completeness, it is to be mentioned that, the indentations 16 and 17 are offset, like in the above-cited patent, longitudinally from one another on the opposite edges of the ribbons 11a and 11b so that a narrow neck portion 18 is formed between each pair of indentations 16 and 17 that has its narrowest portion inclined at a small angle of, say, 30° to 40° with respect to the transverse width of the ribbons 11a and 11b. The successive pairs of indentations 16 and 17 are formed such that each neck portion 18 is inclined at an angle different from that of the respective preceding neck portion 18. In a currently preferred implementation, the absolute values of such angles are substantially the same, but each respective neck portion 18 is inclined in a direction from the transverse width of the ribbon members 11a and 11b which is opposite to that of the respective preceding or succeeding neck portion 18 as considered in the longitudinal direction of the ribbon arrangement 11.
A clip or retainer member 19 is applied around each neck portion 18. Each retainer member 19 is advantageously constituted by a small piece of sheet material that is relatively stiff compared to that of the ribbons 11a and 11b. The retainer member 19 may comprise, for example, a piece of relatively thin and stiff synthetic plastic material, e.g. a cellulose plastic material. The retainer member 19 is provided with a central aperture dimensioned to receive a sandwich including the narrow neck portions 18 of the ribbons 11a and 13a and 13b received between them, and has a slit extending from the central aperture all the way to its outer periphery to allow the introduction of the sandwich into the aperture. The retainer member 19 is applied by flexing it slightly to open the slit and by passing the sandwich through the thus widened slit. Once the sandwich is in the aperture, the flexing forces are discontinued and the slit closes again, keeping the sandwich securely in the aperture. Thereafter, the neck portions 18 are received in the aperture with a degree of snugness sufficient for the retainer member 19 to be restrained from moving longitudinally of the ribbons 11a and 11b and to adopt and maintain the orientation or inclination of the neck portions 18. Each retainer member 19 is thus inclined substantially at the same angle as the narrow neck portions 18 relative to the transverse width of the ribbons 11a and 11b. Yet, on the other hand, even the neck portions 18 of the ribbons 11a and 11b confine the drawstrings 13a and 13b loosely enough so that the drawstrings 13a and 13b can be pulled relatively freely between the neck portions 18.
When the retainer members 19 are constructed, and mounted on the ribbon arrangement 11, in the manner described above, then each of them is inclined, in the position of the adorning article 10 that is depicted in FIG. 1, at the same angle as the aligned neck portions 18, and is in the form of a small plate presenting planar upper and lower faces extending generally perpendicularly to a plane that is flanked by the ribbons 11a and 11b, these faces being inclined with respect to the transverse width of the ribbons 11a and 11b. In the example presented here, each of such retainer members is inclined in a direction or sense opposite to that of the respective preceding or succeeding retainer member 19.
While the construction of the retainer members 19 that has been described above is particularly advantageous, if for no other reason than because it does not require the use of any tools for the assembly of the retainer members 19 with the sandwich including the ribbon arrangement 11 and the drawstring arrangement 13, it is also contemplated by the present invention to use other constructions of the retainer members 19 instead, for instance, that including a length of a deformable metal wire encircling and clamped around the aligned neck portions 18. Even then, however, the principle of causing the retainer members 19 to assume respective inclined positions is adhered to. Moreover, as will be appreciated, in order to locate the retainer members 19 on and orientate them at the desired angles with respect to the ribbons 11a and 11b, it is not absolutely necessary (albeit it is advantageous) to give the indentations 16 and 17 the illustrated V-shape. Rather, to give an example, a simple cut may be formed inwardly from each edge of each of the ribbons 11a and 11b, such cuts being substantially aligned with one another as between the ribbons 11a and 11b but offset from one another as far as the respective ribbon 11a or 11b is concerned to provide respective narrow lands or intervening portions around which the retainer member 19 may be clipped.
In those respects that have been described above, the adorning article 10 has so much in common with that described in the above patent that reference may be had to the latter for any details that may need clarification. However, the article 10 of the present invention also differs from that described in the patent in details that are both substantial and substantive.
More particularly, as already mentioned before, the article 10 of the present invention includes the two branches 12a and 12b that effectively double or at least substantially increase the amount of the ribbon material that is available beyond the stem 12c for the formation of a bow. It should be noted in this respect that the drawstrings 13a and 13b, while passing side-by-side with one another through the stem 12c, are separated at the upper end of the stem 12c as considered in FIG. 1 to each individually enter a different one of the branches 12a and 12b and pass next to and/or between the segments 15a.3 (and 15a.0) and 15a.2 and 15a.1, on the one hand, and the segments 15b.3 (and 15b.0) and 15b.2 and 15b.1, respectively. They are connected, such as by respective knots, to the respective crease regions 14a and 14b situated between the segments 15a.1 and 15a.2 and 15b.l and 15b.2 and/or to the respective retainer members 19 if present thereat (they would not have to be if those segments 15a.1 to 15b.2 were about one-half in length of the others, and in that case the indentations, incisions or notches 16 and 17 could be dispensed with as well at those locations). Of course, respective retaining members 19 are used to connect the free ends of the folded-over segments 15a.1 and 15b.1 to the neck portions 18 disposed between the segments 15a.2 and 15a.3 or 15b.2 and 15b.3.
Having so described the construction of the adorning article 10, its conversion from its substantially fiat or developed precursor state of FIG. 1 to its final or bow state depicted in FIG. 4 of the drawing will now be explained in some detail. In use, the article 10, which is distributed and stored prior to use in its flat form, is converted into a decorative pom-pon or rosette-like bow by first grasping the free (lower) ends of the drawstrings 13a and 13b in one hand while simultaneously holding a portion of the segments 15a.n and 15b.n adjacent the retainer member 19 that is situated next to such free drawstring ends lightly between a finger and the thumb of the other hand. The drawstrings 13a and 13b are then pulled outwardly at about the same pace, with the affected finger and thumb of the aforementioned other hand being in engagement with the aforementioned retainer member 19, so that the segments 15a.1 to 15b.n are gathered up into respective loops.
As revealed in FIG. 3 of the drawing, barring unforeseen complications, this gathering process commences at the two branches 12a and 12b, that is, with the segments 15a.1 to 15b.3 contained in them. This preference for the location at which the gathering process commences is attributable, at least in part, to the fact that the segments 15a.3 and 15b.3 are not doubled up, that is they do not have any counterparts juxtaposed with them, so that they constitute "weak links" in the chain of deformation. This overcomes any otherwise possibly existing tendency for the loops to start forming, due to frictional engagement of the drawstrings 13a and 13b with the neck portions 18 of the ribbons 11a and 11b, at the end portion at which the ribbons 11a and 11b are being held, or even elsewhere. It will be appreciated that such an improper commencement of the gathering process would result in irregularities in the loops which would have to be straightened out eventually, in a very laborious manner. Of course, once the gathering process has started properly, it will continue in the same fashion, that is from above to below as seen in FIG. 3 of the drawing, in that the already at least partially accomplished segment deformation will "feed forward" through the deformation chain.
Because of their angled orientations, the retainer members 19 tend to seat themselves on the bow loops at angularly skewed or offset orientations. As a result, the successive loops become skewed or angularly displaced relative to one another at different angles about the axis of the drawstring arrangement 13. In other words, instead of superimposing themselves onto one another, the loops become arranged at varying angles around the axis of the drawstring arrangement 1, to provide a desired rosette-like form at least at the region originating from the stem 12c.
The bifurcation of the adorning articles 10, however, brings about another and possibly even more important advantage. More particularly, in contradistinction to the situation encountered before when the loops had a tendency to form a rosette-like pattern throughout, that is lay themselves on top of one another, albeit at an angular offset, and extend substantially radially along parallel planes normal to the longitudinal axis of the drawstring arrangement 13, the finished article 10 of the present invention will exhibit, because of the presence of the branches 12a and 12b, an even more desirable rather intricate, pom-pon like, substantially semi-spherical shape. This is so because the ribbon material of the branches 12a and 12b is forced, so to speak, to vie or compete for the same space and becomes deflected upwardly as considered in FIG. 4 of the drawing in the process, thus filling the space that used to be void in the past.
Once the conversion of the article 10 into its final state is completed, the drawstrings 13a and 13b may be knotted adjacent the free ends of the segments 15a.n and 15b.n located at the underside of the finished article as considered in its preferred position of use corresponding to that shown in FIG. 4, and the remaining free ends of the drawstrings 13a and 13b may be cut off. Alternatively, such remaining free ends may be used for securing the finished adorning article 10 in the desired position relative to a parcel or package to be decorated by the article, or may even be used for tying such a package.
The article 10 may be furnished to the users in its essentially flat precursor form with an adhesive-backed card having an opening through which the free ends of the drawstrings 13a and 13b either extend already, or are to extend. The adhesive-coated surface of such a card may initially be covered by a release paper that is removed by the user after completion of the formation of the finished article 10 in order to assist in or accomplish securing of the finished article 10 to the package or another item to be decorated.
As already alluded to or even explained before, the bow-forming article precursor 10 may be packed flat for storage and transport. So, for instance, the article precursor may be folded about the narrow neck portions 18, with the segments 15a.1 to 15b.n of the stem 12c and branches 12a and 12b being folded one on the other, to provide a compact folded structure.
In another embodiment, the stem portions can be eliminated altogether, it being sufficient to connect the main ribbon sections together at the merger region.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the type described above.
While the present invention has been described and illustrated herein as embodied in a specific construction of an adorning or decorative article, it is not limited to the details of this particular construction, since various modifications and structural changes may be made without departing from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims. | An adorning article includes a pair of elongated ribbons subdivided into consecutive segments connected in succession by respective neck portions, a pair of drawstrings, and a multitude of retainer members that are applied to the neck portions to connect them to one another. Each of the ribbons includes a stem portion and a branch portion merging with one another at a merger region. At least one of the segments of each of the branch portions is folded back into juxtaposition with an adjacent segment of the same branch portion and is connected by a respective retainer member to that of the neck portions that connects the adjacent segment with the next one. | 3 |
BACKGROUND
[0001] This invention relates to techniques for presenting media to a group of users in an online environment. In today's work environment where people often work in offices located in different cities, it is common to do various types of media presentations, such as slide show presentations, using various types of computer networks, such as Intranets or the Internet. Typically, the presentations are done in conjunction with a telephone conference call, so that the participants can listen to and ask questions to the presenter.
[0002] In some cases, the slides used in the presentation are distributed to all the participants before the presentation, for example, through e-mail or by downloading the slides from a server to the participants' computers. During the presentation, each participant views her own copy of the slides on her computer using some kind of slideshow presentation software, for example, the PowerPoint® software application which can be obtained from Microsoft Inc. of Redmond, Wash. A challenge to this approach is to keep the slides synchronized amongst the participants during the presentation. Typically, the moderator must tell the participants whenever he changes slides and verbally state what slide he is on. If a participant were to miss a slide number announcement, he may get confused and not realize that the presenter is talking about a different slide.
[0003] In other cases, no slides are provided to the participants in advance of the presentation. Instead, some kind of web conferencing solution is used. One commonly used web conferencing system is provided by WebEx Communications Inc. of Santa Clara, Calif. In the web conferencing solution, the presenter and participants register with a web service, and during the presentation a bitmap representation of what is shown on the presenter's computer screen is transmitted to all the participants in real time and displayed in a web browser. That is, no special software is required to be installed on the presenter's or participants' computers. However, the participants lack the ability of going back and forth between slides as the presentation is going on, and can only view the slide that is currently selected by the presenter.
SUMMARY
[0004] In general, in one aspect, the invention provides methods and apparatus, including computer program products, implementing and using techniques for synchronizing a media presentation. A locally stored electronic copy of the media presentation is displayed on a presenter's presentation device and a locally stored copy of the media presentation is displayed on each of one or more participants' presentation devices. The presenter's presentation device and each participant's presentation device is operable to communicate with each other through a communications network. In response to the presenter performing an action on the electronic copy of the media presentation on the presenter's presentation device during the media presentation, data pertaining to the action is transmitted through the communications network to each participant's presentation device. The appearance of the media presentation on each participant's presentation device is changed in accordance with the data transmitted from the presenter.
[0005] The invention can be implemented to include one or more of the following advantages. The participants know at all times what slide the presenter is referring to. Only a small amount of information is sent through the computer network to the participants, thereby preserving valuable bandwidth. The presenter can obtain information in real time, or after the presentation, about what slides individual participants, or the group of participants as a whole, spent most or least time on. The presenter can highlight sections of individual slides to indicate to the participants what section of the slide is being discussed. The control of the presentation can be handed off, temporarily or permanently, from the moderator to one of the participants. It is easy for all participants to be redirected to a particular position in the presentation. The presenter can at any time relinquish control to one of the participants. The presenter can be informed when all users have advanced to a particular portion of their respective local copies of the presentation.
[0006] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0007] FIG. 1 shows a flowchart of a process for performing a media presentation in accordance with one embodiment of the invention.
[0008] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0009] Embodiments of the invention will be described below by way of example and with reference to a slide show presentation. It should, however, be noted that the various embodiments of invention are not limited to slide show presentations only, and that the concepts described herein can be applied to other types of media, such video or various types of electronic documents, that is to be shared among a group of users. Furthermore, the operations described herein can be performed by a stand-alone software application, or be integrated partly or entirely in a slide show presentation software application. In the following description, it is assumed that each participant's computer, as well as the presenter's computer is connected to a computer network, such as an Intranet or the Internet, through a wired or wireless connection, such that information pertaining to the presentation can be exchanged between the presenter and the participants through the network.
[0010] As shown in FIG. 1 , a process ( 100 ) for performing a media presentation, in this illustrative example a slideshow presentation, in accordance with one embodiment of the invention starts by an individual copy of the slideshow presentation being distributed to each participant who plans to view the slideshow presentation (step 102 ). The participants can either be selected by the presenter, or sign up to view the presentation in response to a general announcement or invitation, using mechanisms that are well known to those of ordinary skill in the art. This typically occurs some time before the time of the presentation, but in some implementations it is also possible for tentative participants to view a list of ongoing presentations that are available to them on their network, and instantaneously sign up to join the presentation as a participant. In some implementations, a publish-subscribe system is used, which allows the presentation software application to connect to a presenter's calendar system on his computer to obtain a list of the participants of the presentation from a calendar entry. Alternatively, the presenter can manually enter the IP address for the participants. The distribution of the slide show presentation to the participants can be done by any conventional means, such as, for example by e-mail or by the participants downloading the slideshow presentation from a server connected to the computer network.
[0011] Next, the presentation is initiated (step 104 ). This step typically involves the presenter and each participant opening their personal copy of the presentation in some kind of slideshow presentation software application, such as the PowerPoint® application or a similar application. The participants' slideshow presentation software application (or their stand alone application) allows the participant to synchronize their slides with another user, in this case the presenter, by simply selecting that user from a drop-down list or other type of menu. The software then subscribes to that user's activity. An audio connection is also established so that the participants and the presenter can hear each other. In one implementation, the audio connection is established by the presenter and the participants joining a telephone conference call. In other implementations, the audio connection is established using voice over IP (VOIP) technology, such that no separate telephone connection is needed between the presenter and the participants. Instead, the audio is transmitted over the computer network along with the slideshow information.
[0012] The process then keeps checking whether the presenter has selected a new slide (step 106 ). When a new slide is selected by the presenter, slide information is distributed to the participants (step 108 ). In a simple embodiment, when the presenter changes slides, the software broadcasts an integer indicating the new slide number to the participants. The presenter's slide number can then be shown in a particular location on a participant's computer display, or a popup window can be displayed, in which the participant is asked to advance to the next slide. In more sophisticated embodiments, the new slide number is received in the participant's slideshow presentation software, where it automatically triggers the software application to display the same slide that the presenter is viewing. Regardless of which embodiment is used, this allows the participants to always stay current with what slide the presenter is talking about during any point of the presentation, which significantly reduces the chance of confusion among the participants. Furthermore, in all of these implementations, a very small amount of information is passed through the computer network compared to the bitmap images that must be transmitted during web conferencing presentations.
[0013] In some implementations, more sophisticated actions pertaining to the slides can be distributed from the presenter to the participants as well. For example, the presenter may highlight some text on a slide, rearrange the order of the slides, or perform some other kind of operation that affects the content of one or more slides in the presentation. This information can be broadcast as metadata to the participants in addition to the slide number information, and be reflected on their computer screens. For instance, in the case of highlighting text, a unique identifier can be passed that corresponds to the text box object, as well as displacement integers that describe what portion of the text is highlighted.
[0014] Some embodiments of the invention optionally allow the participants to provide feedback to the presenter (step 110 ). This feedback can take several forms. For example, in its simplest form, the control of the slideshow presentation can be temporarily relinquished by the presenter and passed on to one of the participants who may have questions about a particular slide. For example, consider Alice who is presenting a slideshow presentation to the participants Bob and Charlie. If, during the presentation, Bob says to Alice “Wait a second. What about this previous slide you talked about?” Alice, with a click of a button, can view on her slideshow software what slide Bob is currently viewing. Bob doesn't actually have to tell Alice what slide number he is viewing. Alice can also agree to temporarily give Bob control of the presentation, so that he can select specific areas of the slide that he is asking questions about.
[0015] Another type of feedback that can be provided to the presenter is statistical information pertaining to which slides the participants are viewing at any given instance during the presentation. For example, in the above example, Alice may want to keep track of what all the participants are viewing. A portion of Alice's computer screen can be dedicated to a grid of slides where she can see what slide Charlie, Bob, and others are viewing. In some implementations, this information can also be recorded and processed after the presentation is concluded. For example, if Alice is presenting to a remote audience of hundreds of participants she may want to view statistics of what slides where most viewed, or what slides the participants spent the most time viewing, which may give her an indication of which slides are most interesting to her audience.
[0016] Finally, the process checks whether all slides are done (step 112 ), that is, whether the presentation is finished. If all slides are done, the process ends, otherwise it returns to step 106 to determine whether the presenter has advanced to a new slide.
[0017] In some embodiments, the entire presentation can be saved and replayed at a later point in time. This is particularly useful for participants that are unable to attend the live presentation or who can only attend a portion of the live presentation, as it allows them to still obtain the same information at a later point in time. In one embodiment, the presentation is saved as an audio file that contains slide changing queues. This enables a participant to play the audio file and the locally saved copy of the presentation or slideshow will change to reflect the time the presenter spent on each slide.
[0018] The invention can take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment containing both hardware and software elements. In a preferred embodiment, the invention is implemented in software, which includes but is not limited to firmware, resident software, microcode, etc.
[0019] Furthermore, the invention can take the form of a computer program product accessible from a computer-usable or computer-readable medium providing program code for use by or in connection with a computer or any instruction execution system. For the purposes of this description, a computer-usable or computer readable medium can be any apparatus that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
[0020] The medium can be an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system (or apparatus or device) or a propagation medium. Examples of a computer-readable medium include a semiconductor or solid state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), a rigid magnetic disk and an optical disk. Current examples of optical disks include compact disk—read only memory (CD-ROM), compact disk—read/write (CD-R/W) and DVD.
[0021] A data processing system suitable for storing and/or executing program code will include at least one processor coupled directly or indirectly to memory elements through a system bus. The memory elements can include local memory employed during actual execution of the program code, bulk storage, and cache memories which provide temporary storage of at least some program code in order to reduce the number of times code must be retrieved from bulk storage during execution.
[0022] Input/output or I/O devices (including but not limited to keyboards, displays, pointing devices, etc.) can be coupled to the system either directly or through intervening I/O controllers.
[0023] Network adapters may also be coupled to the system to enable the data processing system to become coupled to other data processing systems or remote printers or storage devices through intervening private or public networks. Modems, cable modem and Ethernet cards are just a few of the currently available types of network adapters.
[0024] A number of implementations of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, the invention has been described above by way of example of the participants using computers to view the presentation. However, any type of device capable of displaying a presentation, such as a PDA (Personal Digital Assistant), mobile telephone, or other types of electronic communication devices can be used. The participants have been described above as being identified by IP addresses of their devices, but it is also possible to identify participants' devices through other methods, such as, RFID (Radio Frequency Identification) tags or Bluetooth devices that know they are near a device that is somehow associated with the presentation, for example, close to a telephone that will be used in the presentation, or inside a conference room that will be used for the presentation. Accordingly, other embodiments are within the scope of the following claims. | Methods and apparatus, including computer program products, implementing and using techniques for synchronizing a media presentation. A locally stored electronic copy of the media presentation is displayed on a presenter's presentation device and a locally stored copy of the media presentation is displayed on each of one or more participants' presentation devices. The presenter's presentation device and each participant's presentation device is operable to communicate with each other through a communications network. In response to the presenter performing an action on the electronic copy of the media presentation on the presenter's presentation device during the media presentation, data pertaining to the action is transmitted through the communications network to each participant's presentation device. The appearance of the media presentation on each participant's presentation device is changed in accordance with the data transmitted from the presenter. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority of the European Patent Application No. 09405097.8, filed on Jun. 5, 2009, the subject matter of which is incorporated herein by reference.
BACKGROUND
[0002] The invention relates to a production line for producing books comprising a book casing and a therein encased book block. The production line comprises a casing-in machine arranged at the conveying end of the production line, used for encasing a book block inside a book casing, and a processing section. The processing section comprises additional processing stations with processing devices assigned at partial distances or clocking intervals along the processing section. A book block can be advanced along the processing stations of the processing section for processing a book block spine. The processing stations comprise, in the conveying direction of the book blocks, a feed station for supplying the processing section with book blocks, a takeover station for taking over the book blocks, an adhesive-application station for spreading adhesive onto the book block spines, a backing station for attaching a backing strip and, if applicable, at least one headband, as well as a pressing station for pressing the backing strip or a headband against the book block spine, all arranged in the above sequence. The book blocks can be supplied successively and in a clocked manner to the processing stations with the aid of a conveyor and with the spines facing the processing devices.
[0003] For structural and arrangement reasons, the partial distances, also called the clocking intervals, between the processing stations are normally uniform along a conveying section for the takeover station, the following adhesive application station and the backing or headband-application station, but are farther apart by approximately 40 mm than the regular partial distances or clocking intervals for the conveying section assigned to the feed station.
[0004] Book production lines of this type are disclosed, among other things, in German patent document 43 34 224 A1, German patent document 43 34 225 A1, Swiss patent document 694 016 A5 and European patent document 1 894 739 A1.
[0005] With the disclosed book production lines, the conveying device and the processing stations are connected to a central drive motor. This arrangement requires a high driving power and results in high mass moments of inertia leading to the use of heavy gears and other involved drive elements. In recent years, the market for printed products, especially books, has shifted to extremely small editions of short-run productions for which the use of individual drives with angle of rotation controlled motors is suitable. Among other things, these motors offer the advantage that complete conveying sections can be stopped in case of a malfunction or that only the remaining production run can be processed out. Book blocks which are located downstream of the malfunction location on the production line can be processed further, meaning the portion of the production line that follows the malfunction can be emptied. As a result, waste material is noticeably reduced for very small editions, thus advantageously impacting the costs.
[0006] A traditional book production line normally comprises three conveying sections along a conveying line. The first conveying section is a feed or transfer section in which the book blocks are conveyed in a clocked manner, aligned and then transferred to the second conveying section for additional processing stations that follow in the downstream direction.
[0007] The second conveying section provides additional processing stations, as seen in the conveying direction, with a takeover station in which the book blocks are respectively positioned with the aid of a device on the feed section before being picked up by the movable chain mouth of side-by-side circulating chain conveyors that form the additional conveying section for the additional processing stations. The adhesive-application station, the backing station and the pressing station are located along this conveying section, as seen in conveying direction, wherein the adhesive is applied while a book block is moving through and after it is picked up by the chain conveyor, and wherein the subsequent backing and pressing operations occur successively while the book block is stopped.
[0008] The third conveying section is formed by the casing-in machine, in which six conveying elements circulate, for example in the form of a bucket conveyor.
[0009] The processing of small editions, for example involving 1 to 20 copies of book blocks of the same thickness, requires a relatively high share of the total expenditure for the set-up or conversion time. With traditional, standard book production lines, the requirements for producing a single-book edition can only be realized with difficulty and at high cost.
SUMMARY
[0010] It is an object of the present invention to create a book production line that makes possible a considerable improvement in the efficiency of the book production line when processing small editions of books having different thicknesses.
[0011] The above and other objects are accomplished according to one aspect of the invention wherein there is provided a production line for producing books including a book casing and a therein encased book block which, in one embodiment, includes a casing-in machine, arranged at a conveying end of the production line, to encase a book block in a book casing. The production line further includes a processing section upstream of the casing-in machine. The processing section includes processing stations arranged at clocking intervals along the processing section to process a book block spine. The processing stations include processing devices. The processing section includes, in sequence of the conveying direction of the book blocks, a first processing station group. The first processing station includes a feed station to supply book blocks to the processing section. The processing section further includes a second processing station group including, in sequence of a conveying direction of the book blocks, a transfer station to take over the book blocks, an adhesive-application station to apply adhesive to the book block spines, a backing station to attach a backing strip, and a pressing station to press the backing strip against the book block spine. The production line further includes a conveyor to successively supply the book blocks in clocked operation to the processing stations with the book block spines exposed and pointing upward toward the processing devices. The conveyor includes a first conveying section assigned to the first processing station group, the first conveying section including a first individual drive. The conveyor further includes a second conveying section assigned to the second processing station group, the second conveying section including a second individual drive. The production line further includes a control unit operatively connected to the first individual drive and second individual drive to change the clocking interval length along the processing section.
[0012] As a result, the length of the clocking intervals can be changed along the conveying section assigned to the processing stations.
[0013] A conveyor for the casing-in machine may be synchronously driven with the clocking rate of at least one of the conveying section for the feed station or the conveying section for the processing stations in order to coordinate the book production line.
[0014] The clocking interval length along the conveying section between the processing stations may be adjustable or re-adjustable to multiple lengths to achieve a higher performance efficiency.
[0015] With the herein described book production line, the clocking interval can be adjusted or re-adjusted to twice the length along the conveying section assigned to the processing stations, thereby avoiding any change in the coordination of the conveying sections.
[0016] Of course, it makes sense if the conveying sections for the processing stations and the feed station in which the book blocks are integrated into the process have approximately the same or different clocking interval lengths for large as well as small editions.
[0017] For the sake of simplicity, a multiple-length clocking interval on the conveying section assigned to the processing stations can be triggered via the control unit, based on a specific circulation number of uniformly thick book blocks.
[0018] The control unit may therefore be connected to a program and data memory for controlling the course of the processing of one or a plurality of successively following book block editions.
[0019] A change in the clocking interval length along the conveying section assigned to the processing stations to a clocking interval several times longer may occur for small editions ranging from one to five hundred book blocks so performance efficiency is improved.
[0020] The conveying section assigned to the processing stations of the processing section, arranged upstream of the casing-in machine as seen in book block conveying direction, may comprise alternately arranged processing stations designed for processing book blocks which are stopped or processing stations for processing book blocks that are moving through, to achieve a higher performance efficiency.
[0021] The end of the conveying section that is assigned to the processing stations in conveying direction of the book blocks, may therefore be a processing station which takes over the book blocks while the book blocks are stopped. The processing stations may then achieve a favorable clocking interval arrangement with an uneven clocking interval length between the conveying sections.
[0022] The book production line may be embodied so the conveying section that is assigned to the processing stations can be adjusted or re-adjusted during the processing of the book blocks.
[0023] It has proven useful if the individual drives for the conveying sections assigned to the processing stations and the feed station, respectively the casing-in machine, are provided with angle of rotation controlled electric motors, also called servo motors, which are operatively connected to the control unit, thus also resulting in an efficient structural design.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The present invention will be more readily understood from the following detailed description when read in conjunction with the accompanying drawings, in which:
[0025] FIG. 1 A perspective view of a schematically shown book production line for the processing book blocks at clocked intervals along a processing section which ends in a casing-in machine; and
[0026] FIG. 2 The book production line according to FIG. 1 with multiple clocked interval processing along the processing section.
DETAILED DESCRIPTION
[0027] FIG. 1 schematically shows a book production line 1 for producing books 4 comprising a book casing and a therein encased book block 3 . The conveying end of the book production line 1 is formed by a processing station which is also referred to as casing-in machine 5 and is described, for example, in European patent documents 1 780 037 A1 and 1 780 038 A1, as well as in the German patent document 19729529, the disclosures of which are incorporated herein by reference.
[0028] The casing-in machine 5 is used for applying adhesive to the outside surfaces of the book block 3 and for pressing a book casing 2 against the adhesive-coated outside surfaces of a book block 3 . For this, the casing-in machine is provided with a bucket-type conveyor 6 , having a traction device that circulates in a vertical plane and thereto attached, jib-like extending saddle plates 8 for holding and transporting the book blocks 3 which are supplied by the processing section 20 .
[0029] FIG. 1 furthermore shows the instantaneous position of six saddle plates 8 along the illustrated movement path where they have a nearly horizontal upper edge for accommodating the book blocks 3 . The book blocks 3 are moved in the conveying direction F of the book blocks 3 along the processing section 20 and over a block divider (not shown herein) with the opened front, also called the fore edge, pointing downward. The block divider spreads out each book block 3 in the center so the book block 3 is in a position for takeover by the conveyor 6 in which the saddle plates 8 take over the book blocks by dipping from below into the slightly spread-out book blocks 3 .
[0030] Following this, each book block 3 now straddling the saddle plates 8 moves vertically upward through an adhesive-application device, not shown herein, in which a book casing 2 supplied on the side of a pressing device (not visible herein) is pressed against the adhesive-coated outside surfaces of a book block 3 , also called the fly leaves of a book block 3 . Further along the conveying path of the casing-in machine 5 , the just produced books 4 reach a delivery station 9 where they are taken over by a delivery element 10 and are deposited on a delivery belt, not shown herein.
[0031] Arranged upstream of the casing-in machine 5 is a processing section 20 , along which additional processing stations are arranged at regular partial distances, also called clocking interval lengths. The processing stations include processing devices for processing a book block spine 21 . As seen in conveying direction F for the book blocks 3 , a feed station 13 with a feeding device 14 for supplying the following processing station is arranged at the start of the processing section 20 .
[0032] The clocked feeding of the book blocks 3 is realized, for example as shown in FIGS. 1 and 2 , with the aid of a star rotor 15 driven around an axis extending parallel to the conveying direction F at the clocking rate of the conveying section 16 for the feed station 13 . The star rotor 15 is provided along the circumference with six holding compartments for respectively supplying one book block 3 with its fore edge leading. The star rotor 15 deposits the book block 3 respectively with the fore edge onto a guide surface (not shown herein) where it is transported in synchronization with the clocking rate of the processing section 20 by a finger. The finger acts upon the rear edge of the book block and is positioned on a conveying chain (not visible) that is assigned to the feed station 13 , respectively a feed device 14 . The feed station 13 , respectively the feed device 14 , forms a separate feed section 16 which advances by several clocking intervals for transferring the book blocks 3 to the following processing station, a takeover station 17 of a conveying section 18 of the processing section 20 , which follows in conveying direction F of the book blocks 3 .
[0033] The separate conveying sections 16 , 18 are provided with separate drives 22 , 23 which are operatively connected to a joint control unit 24 . The individual drives 22 , 23 can be embodied as geared motors with an angle of rotation controlled electric motor and can be controlled individually or separately by the control unit 24 . That is to say, the conveying sections 16 , 18 can be operated with differently long clocking intervals. For the matter at hand, the conveying section 18 , arranged downstream of the conveying section 16 for the feed station 13 , as seen in conveying direction F of the book block 3 , can be adjusted or re-adjusted to clocking intervals which are multiple times, for example two times, longer than is provided between the processing stations. A slight difference in the clocking interval length between the conveying sections 16 and 18 , for example a clocking interval length that is longer by 40 mm in the conveying section 18 as compared to the conveying section 16 , does not impact the functions or movements of the processing section 20 .
[0034] To synchronize the clocking intervals over the complete book processing line 1 , it may be useful if the conveyor 6 that is assigned to the casing-in machine 5 is synchronously operated with the clocked conveying speed of one of the two or both conveying sections 16 , 18 . The transfer of the book blocks 3 from the conveying section 16 to the conveying section 18 can be realized, for example, with a conveying clamp 19 as described in European patent document 09405082.0, the disclosure of which is incorporated herein by reference, which transfers the book block 3 over two clocking intervals to the conveying section 18 . The conveying section 18 , which is distinguished by the processing of a book block spine 21 , is provided at the front end as seen in conveying direction F of the book blocks 3 , respectively at the intake for the conveying section 18 , with the aforementioned takeover station 17 in which the book blocks 3 are initially stopped until they are gripped on the conveying section 18 .
[0035] This downstream arranged conveying section 18 of the conveyor assigned to the processing section 20 is formed by two conveying belt sections 25 , 26 , arranged on the side at a uniform distance to the longitudinal center axis that extends through the longitudinal center plane for the upright standing books blocks 3 , of two adjacent and synchronously circulating conveying belts or conveying chains 27 , 28 , wherein the conveying belts 27 , 28 are driven around the approximately vertical axes of deflection rollers that are not visible herein.
[0036] The intake region 29 of the conveying section 18 , which is arranged upstream in conveying direction, projects counter to the conveying direction F over the transfer position for the conveying clamp 19 , respectively the clamping jaws 30 , 31 which form the conveying clamp, thus resulting in a super imposition of the conveying sections 16 , 18 . The intake region 29 forms a chain mouth 34 which is opened when a book block 3 is supplied with the aid of the conveying clamp 19 that is mounted on a sled or carriage. For this, the intake region 29 is expanded in a V shape to narrow down in a wedge-shaped taper in conveying direction F, thus ensuring a careful takeover of the book blocks 3 by the conveying section 18 .
[0037] The opening and closing of the chain mouth 34 is achieved by pivoting to the side around vertical axes 35 , 36 of the end sections 32 , 33 that form the intake region of the conveying belts 27 , 28 , wherein the empty belt sections of the conveyor belts 27 , 28 fit flush against side-mounted support rollers 37 , 38 . To change the conveying gap between the conveying belt sections or the working belt sections of the conveying belts 27 , 28 for adapting these to the thickness of the book blocks, the latter can be adjusted or readjusted uniformly with respect to the mutual spacing.
[0038] The takeover station 17 is followed in conveying direction F of the book blocks 3 , advanced by one clocking interval, by an adhesive application station 39 which is indicated by an adhesive roller 40 . The latter is driven to roll off the book block spine 21 for applying the adhesive, such that the book block 3 passes through the adhesive application station 39 without stopping and is stopped only after the next clocking interval in the backing station 41 , in which a backing material strip 43 is supplied from a roll 42 to the adhesive-coated book block spine 21 . Following two more clocking intervals in conveying direction F, a pressing station 44 is arranged on the processing section 20 in which the backing material 43 , placed onto the book block spine 21 , is pressed against the adhesive-coated book block spine. The book blocks 3 reach the casing-in machine 5 , respectively an available saddle plate 8 , over the course of two or four clocking intervals following the pressing station 44 . The conveying sections 16 , 18 , which function as a conveying device for the processing section 20 , are driven separately with the aid of individual drives 22 , 23 that are provided with angle of rotation controlled electric motors. The conveyor 6 of the casing-in machine 5 is also advantageously provided with a separate drive 45 which operates synchronized with the clocking rate of the at least one or both individual drives 22 , 23 for the conveying sections 16 , 18 via the joint control unit 24 .
[0039] FIG. 2 shows the book production line 1 during the processing of book blocks 3 , using a double clocking interval in conveying direction F between two processing stations 17 , 41 , 44 , 5 in which a book block spine 21 is processed while the book block 3 is stopped. In particular small and extremely small editions make it possible to move with multiple or double clocking intervals along the conveying section 18 (as shown in the embodiment) over the processing section 20 .
[0040] One difference lies in the manner in which the processing stations are arranged along the conveying section 18 . An idle stroke step 46 may be provided between the backing station 41 and the pressing station 44 to obtain a double clocking interval along the conveying section 18 , respectively a double stroke length for the clocking strokes.
[0041] With large editions, the resulting gap can be closed during normal operations by moving the pressing station 44 to be positioned downstream of the backing station 41 , for example by having a mobile station, thereby closing the gap once more. The adhesive-application station 39 does not present an obstacle for a double clocking interval since adhesive is applied to the spine 21 of a book block while it is passing through.
[0042] It is understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | A production line including a casing-in machine and a processing section upstream of the casing-in machine. The processing section includes processing stations arranged at clocking intervals along the processing section to process a book block spine. The processing section includes a first processing station group and a second processing station group. The production line further includes a conveyor to successively supply the book blocks in clocked operation to the processing stations. The conveyor includes a first conveying section assigned to the first processing station group, the first conveying section including a first individual drive, and a second conveying section assigned to the second processing station group, the second conveying section including a second individual drive. The production line further includes a control unit operatively connected to the first individual drive and second individual drive to change the clocking interval length along the processing section. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. 119(e) to U.S. Provisional Application No. 60/511,863, filed Oct. 16, 2003, which application is incorporated herein by reference.
GOVERNMENT FUNDING
[0002] This invention was made with Government support of the United States Department of Agriculture through Iowa Biorenewable Technology and Byproduct Consortium. The United States Government has certain rights in this invention.
BACKGROUND OF THE INVENTION
[0003] Recently, advances have been made which strike a more desirable balance between maintaining fuel efficiency and reducing the percentage of particulate emissions in fuels through the use of blends of petroleum based fuel with alkyl esters of the fatty acids contained in vegetable oils or animal fats. These alkyl esters are commonly referenced to as “biodiesel”. Substantially pure alkyl esters, such as methyl or ethyl esters of fatty acids, are generally preferred in biodiesel over the use of the vegetable oils and animal fats themselves because the alkyl esters have a viscosity that is more appropriate to diesel fuel. Through the use of these fuel blends, researchers have attained reductions in particulate emissions from diesel engines. See, e.g., M. Bender, Bioresource Technol., 70, 81 (1999); M. Diasakou et al., Fuel, 77, 1297 (1998); T. Ogoshi et al., J. Am. Oil Chem. Soc., 62, 331 (1985).
[0004] The production of biodiesel has received also extensive interest as a result of this fuel's desirable renewable, biodegradable, and nontoxic properties. See, e.g., G. J. Suppes et al., J. Am. Oil Chem. Soc., 78, 839 (2001); G. Kildrian et al., op. cit., 73, 225 (1996); J. Encinar et al., Ind. Eng. Chem. Res., 38, 2927 (1999). These fatty acid alkyl esters can be prepared by the transesterification of triglycerides in vegetable oils with short-chain alcohols (e.g., methanol and ethanol) using homogeneous alkali catalysts such as alkoxides. For example, soy diesel (methyl soyate) is made commercially by an energy and labor-intensive process wherein soybean oil is reacted with methanol at 140-150° F. (sometimes under pressure) in the presence of sodium methoxide. Isolation of the desired methyl soyate from the highly caustic (toxic) catalyst and other products such as glycerol, involves a precise neutralization process with strong acids, such as hydrochloric acid (HCl), and extensive washes with water to remove the resulting sodium chloride (NaCl) salt. Also, because of glycerol's high boiling point, it must be separated from the sodium chloride salt by vacuum distillation in an energy intensive operation. As more alkyl soyates with different alkyl functional groups, such as ethyl and isopropyl soyates, are being rapidly developed to meet the growing needs of various applications, the level of difficulty in separating the corresponding catalysts, e.g., sodium ethoxide and sodium isoproxide catalysts, respectively, will unavoidably escalate due to the increasing solubility of these basic catalysts in the reaction mixture. Therefore, biodiesel is currently not cost competitive with conventional diesel fuel.
[0005] To improve the economic outlook of biodiesel and alkyl esters in general, the feedstock selection becomes critical. In particular, oil feeds containing high free fatty acid content, such as found in beef tallow or yellow grease, are significantly less expensive than vegetable oils, such as soybean or rapeseed oil (F. Ma et al., op. cit., 37, 3768 (1998). These high free fatty acid feedstocks present significant processing problems in standard biodiesel manufacture since the free fatty acid is saponified by the homogeneous alkali catalyst that is used to transesterify triglycerides leading to a loss of catalyst as well as increased purification costs (D. G. B. Boocock et al., J. Am. Oil Chem. Soc., 75, 1167 (1998).
[0006] One approach for improving the processing of high free fatty acid oils is to first esterify the free fatty acids to alkyl esters in the presence of an acidic catalyst such as a mineral acid. The pretreated oils in which the free fatty acid content is lowered to no more than 0.5 wt % can then be processed under standard transesterification reaction conditions (H. N. Basu et al. (U.S. Pat. No. 5,525,126)). This pretreatment step has been successfully demonstrated using sulfuric acid (S. Koona et al., European Pat. No. 566047 (1993)). Unfortunately, use of the homogeneous sulfuric acid catalyst adds neutralization and separation steps as well as the esterification reaction to the overall process.
[0007] Surfactant-templated mesostructured materials have received a great deal of attention as potential catalysts, sensors and adsorption agents owing to their combination of extremely high surface areas and ordered, flexible pore sizes. For example, mesoporous sieves of the type MCM-41 are prepared by thermal treatment of silaceous gels formed by the polymerization of alkoxysilanes around surfactant micelle templates in aqueous base, followed by removal of the surfactant to yield a matrix comprising fine pores in a cylindrical array. The physical and chemical properties of these mesoporous materials can be modified by incorporating functionalized organic groups, either by grafting on the preformed mesopore surface or by co-condensation using functionalized substituted trialkoxy silanes during synthesis. See, e.g., D. Zhao et al., Science, 279, 548 (1998); A. Stein et al., Adv. Materials, 12, 1403 (2000); and W. M. Van Rhijn et al., Chem. Commun., 317 (1995). Organic-inorganic hybrid mesoporous silicas formed by co-condensation with thio-containing silanes, followed by oxidation of the SH groups yield pores functionalized with sulfonic acid groups. The direct co-condensation synthesis technique in which the mesostructure and functional group are simultaneously introduced, appears to be a desirable route for incorporating functional groups because it has been shown that it increases the concentration of the sulfonic groups in the mesoporous silica relative to post-formation grafting (I. Diaz et al., Stud. Surf. Sci. Catal., 135, 1248 (2001). One approach demonstrated previously involves one-step synthesis based on the simultaneous hydrolysis and condensation of tetraethoxysilane (TEOS) with 3-(mercaptopropyl)trimethoxysilane (MPTMS) in the presence of template surfactant using in situ oxidation of the thiol groups with H 2 O 2 . Melero et al. has shown that the acid strength of the sulfonic groups in the mesoporous materials can be adjusted by choice of the organosulfonic precursor (J. A. Melero et al., J. Mater. Chem., 12, 1664 (2002).
[0008] For example, mesoporous catalysts containing sulfonic acid groups and, optionally internal methyl groups have been reported to be efficient catalysts in the esterification of glycerol with fatty acids, where high yields of mono-esters are obtained. See, e.g., W. D. Bossaert et al., J. Catal., 182, 156 (1999); I. Diaz et al., Appl. Catal. A., 242, 161 (2003); I. Diaz et al., J. Catal., 193, 295 (2000); D. Magolese et al., Chem. Mater., 12, 2448 (2000). Similar SO 3 H silicates have been used to tetrahydropyranylate ethanol. M. H. Lin et al., Chem. Mater., 10, 467 (1998). Mesoporous silica functionalized with arenesulfonic acid groups has been used to catalyze the Fries rearrangement of phenyl acetate to 2- and 4-hydroxyacetophenones. J. A. Melero et al., J. Mater. Chem., 12, 1664 (2002).
[0009] However, a continuing need exists for a simple method to form (lower)alkyl esters of fatty acids in the environment of triglyceride-containing feedstocks.
SUMMARY OF THE INVENTION
[0010] The present invention provides a method to prepare a fatty acid (C 1 -C 3 ) alkyl esters from a feedstock, such as a vegetable or an animal oil, comprising one or more fatty acid glycerol esters such as mono-, di- or tri-glycerides, and free fatty acids, comprising combining the feedstock, a (C 1 -C 3 ) alcohol and an acidic mesoporous silicate under conditions wherein the mesoporous silicate catalyzes the formation of the corresponding fatty acid (C 1 -C 3 ) alkyl ester of the free fatty acids and optionally glycerol. Thus, in one embodiment, the present invention provides a method to transesterify an ester comprising combining the ester, a (C 1 -C 3 ) alcohol and an acidic mesoporous silicate under conditions wherein the mesoporous silicate catalyzes the formation of the (C 1 -C 3 ) alkyl ester of the acid portion of the ester and the corresponding free alcohol of the ester. In another embodiment, the present invention provides a method to prepare a lower alkyl ester of a fatty acid comprising combining the fatty acid, a lower alkanol and an acidic mesoporous silicate under conditions wherein the silicate catalyzes the formation of the corresponding lower (alkyl) ester. In a preferred embodiment, the fatty acid is present in an organic or synthetic feedstock such as an animal or vegetable oil that comprises a major portion of glycerol fatty acid esters.
[0011] Preferably the fatty acid portion of the ester or glyceride is derived from a (C 8 -C 22 ) fatty acid, preferably a (C 10 -C 18 ) fatty acid, which is a saturated alkyl ester that optionally comprises 1-3 CH═CH moieties in the alkyl chain. The (C 1 -C 3 ) alcohols are preferably methanol, ethanol, propanol or i-propyl alcohol, although higher alkanols such as (C 4 -C 6 ) alkanols may be useful in some applications. The alcohol is preferably used in a molar excess over the starting material acid and/or ester component of the feedstock, since such esterification/transesterification reactions are highly reversible.
[0012] The acidic mesoporous silicate is preferable particulate or granular, and can have a preselected shape such as spherules or rods. The pore size must be sufficient to admit triglycerides and/or fatty acids, and to permit the release of fatty acid esters and/or glycerol. Pore sizes preferably can range from about 1.0-50 nm, preferably about 2-10 nm in diameter. Larger diameters of may be useful to process certain oils. The silicate comprises acidic groups immobilized by linkage to the interior pores and optionally to the exterior surface of the silicate matrix. Useful acidic groups comprise sulfonic acids, sulfinic acids, phosphoric acids, phosphinic acids, boronic acids, selenic acids and mixtures thereof, preferably linked to the silicate matrix via inert organic groups, such as alkyl, alkenyl, arakyl, alkaryl, aryl, and the like. Thus, the functionalized mesoporous silicate functions as a bioinert, heterogenous catalyst that can be readily separated from the reaction products.
[0013] Preferably, the esterification/transesterification reaction is carried out at a relatively low temperature, e.g., of about 20-150° C. Although solvent may not be necessary for liquid feedstocks, the reaction can be carried out in the presence of a polar aprotic solvent such as an ether, e.g., THF, dialkylethers, alkoxypolyols, and the like.
[0014] As used herein, the term animal oil or vegetable oil includes triglyceride-containing materials from plants (seeds and vegetables), mammals, birds and fish and includes those materials that are solid at room temperature (fats such as lard, tallow, hydrogenated vegetable oils, grease, etc.) as well as materials recognized as oils, such as soybean oil, olive oil, safflower oil, sunflower seed oil, linseed oil, cottonseed oil and the like.
[0015] As used herein, the term “alkyl” includes (C 1 -C 12 ) alkyl; “lower(alkyl)” includes (C 1 -C 3 ) alkyl.
[0016] Soybean oil typically contains triglycerides of oleic acid 26%, of linoleic acid 49%, of linolenic acid 11%, of saturated [alkyl] acids 14%. Free fatty acids are usually less than 1%. Phospholipids (lecithin) 1.5-4%. Another 0.8% consists of stigmasterol, sitoserols, and tocopherols. The phospholipids can be removed by refining with alkali.
[0017] Thus, in preferred embodiments, the invention provides a method to use sulfonic acid-functionalized mesoporous solid silicate catalysts to effectively convert fatty acid-containing oil feedstocks to the corresponding fatty acid esters (biodiesel) and triglycerides that can be further processed to yield fatty acid esters and glycerol. The use of such catalysis provides several advantages over conventional transesterification/esterification: 1. The ability to convert fatty acids into esters in alcohol containing solutions, so that the free fatty acid-containing oils, animal fats, and restaurant deep-fry oils can be used as feedstocks for biodiesel production. 2. The catalysts are solids that function as heterogeneous catalysts that can be separated from the reaction mixture and recycled. 3. The catalysts have high surface areas because of their porosity. 4. The pores are sufficiently large to allow passage of the soybean oil and alcohols used in the transesterification process through them. 5. The pores can be chemically modified to allow more rapid passage of large molecules such as vegetable oil molecules through them. 6. The catalyst rapidly and under mild conditions converts soybean oil to soybean oil methyl ester plus glycerol (which are easily mechanically separated). The methyl ester (biodiesel) is a viable biodegradable alternative to petroleum-based fuels. Glycerol has a variety of cosmetic and food uses, but it is also under investigation as a biodegradable alternative to petroleum-based ethylene glycol and propylene glycol in aviation de-icing formulations.
BRIEF DESCRIPTION OF THE FIGURES
[0018] FIG. 1 depicts mesoporous materials with two organosulfonic acid functional groups; a) propylsulfonic groups, b) arenesulfonic groups.
[0019] FIG. 2 depicts scanning electromicrographs 2 ( a ) and 2 ( b ) of the mesoporous materials functionalized as shown in FIG. 1 ( a) and 1 ( b ), respectively.
[0020] FIG. 3 is a graph depicting the catalytic results of esterification of palmitic acid in soybean oil with methanol over different catalysts (85° C.; PA:MeOH=1:20, catalyst: +=5% H 2 SO 4 , •=10% SBA-15-SO 3 H—P123, x=10% Nafion, ∘=10% SBA-15-SO 3 H-L64, □=10% CDAB—SO 3 H—C 16, ⋄=10% Amberlyst 15wet).
[0021] FIG. 4 is a graph depicting the esterification of palmitic acid in soybean oil with methanol (85° C.; PA:MeOH=1:20, catalyst is 10% SBA-15-SO 3 H—P 123) showing the effect of external mass transfer (▪=200 rpm, •=350 rpm, □=500 rpm).
[0022] FIG. 5 is a graphical comparison of activation energy on the esterification of palmitic acid in soybean oil with methanol (PA:MeOH=1:20).
[0023] FIG. 6 is a graph depicting the esterification of palmitic acid with methanol (85° C.; PA:MeOH=1:20, catalyst: □=5% H 2 SO 4 , ∘=10% pTSA, ▪=10% SBA-5-SO 3 H—P123, •=10% SBA-5-ph-SO 3 H—P123).
[0024] FIG. 7 is a graph comparing the apparent reactivity of the palmitic acid esterifying catalysts (85° C.; PA:MeOH=1:20).
[0025] FIG. 8 is a graph depicting the reaction kinetics of the transesterification of soybean oil to methyl soyate (biodiesel) comprising fatty acid methyl esters and glycerol.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Hereinbelow is described the synthesis and utilization of silica mesoporous materials modified with sulfonic groups for the pretreatment esterification of high free fatty acid oils. The results for the catalytic performance of the mesoporous materials are also compared to commercial acid catalysts.
[0000] Mesoporous Silicates
[0027] Particulate mesoporous silicates typically have a particle size of about 50 nm to about 1 μm. In one embodiment, the mesoporous silicates have a particle size of at least about 100 nm, or preferably at least about 200 nm. In another embodiment, the mesoporous silicates have a particle size of less than about 750 nm. As conventionally prepared, they are spherical, but they have also been prepared under conditions that yield other shapes such as rods. The catalysts of the invention can include mesoporous silicates of any shape, provided the pore structure is suitable for admitting the feedstock acids and/or esters.
[0028] The mesoporous silicate pores typically have a diameter of from about 1-100 nm. In one embodiment of the invention, the pores have a diameter of at least about 2 nm. In other embodiments, the pores have diameters of greater than about 5 nm, or greater than about 10 nm. Typically, the pores have a diameter of less than about 75 nm or less than about 50 nm.
[0029] The acidic mesoporous silicates can be prepared from aqueous dispersions of surfactant micelles of surfactants such as (C 10 -C 20 )alkylamines, C 10 -C 16 alkyl(tri(lower)alkyl)ammonium salts or Pluronic® surfactants in water, followed by introduction of an alkyl orthosilicate, such as tetraethylorthosilicate (TEOS), and one or more functionalized silanes, comprising one or more functional groups that is sufficiently acidic or that can be converted into an acid, such as one more (C 2 -C 20 )alkyl, alkaryl, arakyl, alkaralkyl, arylakenyl, alkenyl, alkenylaryl, or aralkenyl groups substituted with mercapto, chloro, bromo, amino, carboxy, alkoxycarbonyl, sulfonyl or alkynyl-, wherein aryl is preferably C 8 -C 10 aryl and the (C 2 -C 10 )alkyl chain(s) are optionally interrupted by —S—S—, amido (—C(═O)NR—), —O—, ester (—C(═O)O—), and the like. Optionally, silanes functionalized with groups such as (C 1 -C 3 )alkyl, aryl, aralkyl, alkaryl, CF 3 and the like can be co-condensed with the “acidic silanes” to further modify the properties of the surface and of the pores of the silicates. The aqueous mixture is stirred at moderate temperatures until the silicate precipitates, and it is collected and dried. The surfactant “template” is then removed from the pores of the ordered silicate matrix, for example, by refluxing the silicate in aqueous-alcoholic HCl. The remaining solvent can be removed from the pores of the silicate by placing it under high vacuum and/or by heating. The functional groups incorporated on the surface of the pores can be quantified and optionally, can be further modified as by oxidation, reaction with a protected acid equivalent followed by deprotection to yield the acidic silicate, and the like.
[0030] For example, starting components to prepare a representative neutral mesoporous silicate, MCR-4, include one or more quaternary alkyl ammonium surfactants which are added in water to tetraethoxysilane or tetramethoxysilane, optionally followed by additional surfactant. The resulting gel is agitated for another 0.25-60 min. and is divided over two autoclaves. The hydrothermal step is carried out dynamically at about 350-400 K. The resulting white product is filtered, washed extensively with hot H 2 O and EtOH, dried at elevated temperatures in air, and finally calcined for 5-15 h. See, J. S. Beck, J. Amer. Chem. Soc., 114, 10834 (1992).
[0031] Propylsulfonic acid mesoporous silicas. Mesoporous silicas can be modified with a 3-mercapto lower(C 1 -C 4 )alkyl group using (3-mercapto(C 1 -C 3 )alkyl)trimethoxy(or triethoxy)silane as the organosulfonic acid precursor. Deposition of the mercaptoalkyl silane in inert solvent onto a silicate support with controlled water content results in a “coated” material with a monolayer of mercaptoalkyl moieties, while less-covered “silylated” materials are obtained under dry conditions. Alternatively, in the synthesis of a hexagonal mesoporous silica, organofunctional groups are directly incorporated by “co-condensation” of mercaptoalkylsilance and the main Si source (the tetralkoxysilane) in the presence of a neutral surfactant such as a Pluronic®. Representative recipes for the different synthesis procedures are based on literature examples in W. D. Bossaert et al., J. Catal., 182, 156 (1999) and are given below.
[0032] Coated MCM-41-SH. Calcined MCM-41 is hydrated by refluxing for 106 h in water and removed from the suspension by filtration. The wet filter cake is suspended in toluene in a Dean Stark apparatus, and H 2 O/toluene is removed until a translucent suspension is obtained. An excess of mercaptoalkyl silane is added and after stirring overnight without heating, the suspension is refluxed for 1-5 h. The coated material is then washed in a Soxhlet extractor with CH 2 Cl 2 /Et 2 O (50/50) and dried.
[0033] Silylated MCM-41-SH. Calcined MCM-41 is evacuated (overnight, 375-400 K, <10 Pa) and added to a solution of mercaptoalkyl silane in toluene. Toluene was dried over zeolite 4A before use. After 4 h refluxing, the powder is collected and subjected to the same Soxhlet purification as the previous material.
[0034] Coated silica gel-SH. This was prepared by modifying a chromatographic silica gel 60 (70-230 mesh, Fluka) with mercaptoalkyl silane following the same method as used to coat MCM-41.
[0035] CDAB—SH prepared by co-condensation. CDAB—SH was synthesized at room temperature from a gel containing 0.8 parts tetraalkoxysilane, 0.2 parts mercaptopropyl tri(alkoxy)silane, 0.275 parts surfactant, in 100 parts lower(alkanol) and water. The surfactant was first dissolved in the alcohol-water mixture. Then the silane mixture was added and the mixture was stirred for 24 h. The amine template was extracted from the as-synthesized CDAB—SH with boiling EtOH.
[0036] Oxidation procedure and acidification. Materials with immobilized mercaptoalkyl groups were oxidized with H 2 O 2 or nitric acid in a alkanol water mixture. Typically, aqueous 35% H 2 O 2 dissolved in three parts of methanol is used per g of material. After a suitable time, the suspension is filtered, and washed with H 2 O and lower(alkanol). The wet material was resuspended (1 wt %) in acidified H 2 O for another 2-7 h. Finally, the materials are extensively rinsed with H 2 O, dried at an elevated temperature and stored in a desiccator. These acid-activated materials are denoted with the suffix —SO 3 H.
[0037] The mesoporous materials in the examples below were synthesized following the co-condensation procedures of Boessaert et al., J. Catalysis, 182, 56 (1999) and Melero et al., J. Mater. Chem., 12 1664 (2002) with only slight modifications. Tetraethoxysilane (TEOS, 98%, Aldrich) was used as the silica source. The mesoporous silicas were modified using 3-(mercaptopropyl)-trimethoxysilane (MPTMS, 85%, Fluka) without further treatment. The surfactants, CDAB (cetyldimethyl(ethyl)ammonium bromide) (Aldrich), Pluronic® L64 and Pluronic® P123 (BASF Co., USA), were used as purchased. Mesoporous silica synthesized using the CDAB is denoted as CDAB, while those synthesized with the tri-block Pluronic® copolymers were abbreviated SBA-15. See, A. Stein, Adv. Mater., 12, 1403 (2000).
EXAMPLE 1
CDAB-SO3H
[0038] A molar composition of 0.08 TEOS, 0.02 MPTMS, 0.0275 CDAB, 0.89 EtOH and 2.94 H 2 O was used to synthesize CDAB—SH. The amino surfactant was dissolved in an alcohol-water mixture prior to addition of the TEOS-MPTMS mixture. The mixture was aged for 24 hrs at room temperature under continuous stirring. The resulting solid product was filtered and air-dried. The amine template was extracted by refluxing in boiling EtOH for 24 hrs. The thiol groups were oxidized with H 2 O 2 (2.04 g/g solid) in a methanol-water mixture. The suspension was stirred at room temperature for 24 hrs followed by washing with EtOH and H 2 O. The wet cake was acidified in 0.1 M H 2 SO 4 for an additional 4 hrs before being washed thoroughly with H 2 O. The product was then dried at 393 K.
EXAMPLE 2
SBA-15-SO 3 H
[0039] SBA-15-SO 3 H was prepared by dissolving 4 g of Pluronic® surfactant (P123 or L64) in 125 g of 1.9 M HCl at room temperature under stirring with subsequent heating to 40° C. before adding TEOS. Approximately 45 min. was allowed for prehydrolysis of TEOS prior to addition of the MPTMS-H 2 O 2 solution. The resulting mixture with a molar composition of 0.0369 TEOS, 0.0041 MPTMS, and 0.0369 H 2 O 2 was stirred for 24 hrs at 40° C. and thereafter aged for 24 hrs at 100° C. under static conditions. The product was collected and subjected to the same extraction method as previously described.
EXAMPLE 3
SBA-15-ph-SO 3 H
[0040] SBA-15-ph-SO 3 H mesoporous silica functionalized with benzenesulfonic acid groups was synthesized as follows. Pluronic® P123 surfactant (4 g) was dissolved with stirring in 125 ml of 1.9 M HCl at room temperature. After complete dissolution, the solution was heated to 35° C. TEOS (8.76 g) was added dropwise to the solution at a constant temperature of 35° C. After a TEOS prehydrolysis of 45 min, 2.66 mL of 2-(4-chlorosulfonylphenyl)ethyltrimethoxysilane (CSPTMS) solution in methylene chloride (50%, Gelest) was added dropwise (to prevent phase separation). The resulting mixture was stirred for 20 hrs at 35° C. following by aging at 95° C. for another 24 hrs. The molar composition of the mixture for 4 g of copolymer was: 7.4 TEOS: 1 CSPTMS:48 HCl:1466 H 2 O. The solid was isolated via filtration, washed extensively with methanol and dried in the air. The surfactant template was removed by suspending the solid material in ethanol and refluxing for 48 hours. The sulfonyl chloride groups underwent hydrolysis in the acidic media of the reaction. Shown in FIG. 1 are the respective oragnosulfonic acid functional groups introduced into the silicate lattice.
EXAMPLE 4
Synthesis of TPES-MCM Material
[0041] To synthesize the TPES-functionalized mesoporous silica (TPES-MCM), the well-developed cetyltrimethylammonium bromide (CTAB) surfactant-templated co-condensation method of tetraethoxysilane (TEOS) and organosiloxane precursors was modified by using compound 1 as the organosiloxane precursor, as shown in Scheme A.
Synthesis of compound 1:
[0042] 2,2′-Dipyridyl disulfide (8.82 g, 40.0 mmol) was dissolved in 50.0 mL of methanol; 1.6 mL of glacial acetic acid was added as catalyst. To this mixture, 2-mercaptoethanesulfonic acid sodium salt (3.82 g, 20.0 mmol) in 30.0 mL of methanol was added dropwise in 30 min with stirring. The reaction mixture was protected from light and stirred at ambient temperature overnight, followed by solvent evaporation under vacuum. The crude product was repurified by dissolving in a small amount of methanol, followed by ethyl ether precipitation and dried under vacuum to yield compound 1a. 5.14 g, yield=94.0%. 1 H-NMR (300 MHz; DMSO-d 6 ), δ 2.73 (m, 2H, CH 2 ), 3.02 (m, 2H, CH 2 ), 7.24 (d, 1H, ArH), 7.81 (m, 2H, ArH), 8.45 (d, 1H, ArH).
[0043] To synthesize 2-[3-(trimethoxysilyl)-propyldisulfanyl]-ethanesulfonic acid sodium salt (1), compound 1a (1.36 g, 5.0 mmol) was dissolved in 20.0 mL of methanol with 1.0 mL of glacial acetic acid. To this mixture, (3-mercaptopropyl)trimethoxysilane (0.95 mL, 5.0 mmol) in 10.0 mL of methanol was added dropwise. The mixture was protected from light and stirred under nitrogen at room temperature overnight. The reaction mixture was quenched and solvent was evaporated under vacuum. The solid obtained was dissolved in a small amount of methanol, followed by ethyl ether precipitation. The purified product was collected by filtration and dried under vacuum. 5.14 g, yield=74.7%. 1 H-NMR (300 MHz; D 2 O) δ 0.79 (t, 2H, CH 2 (1)), 1.83 (q, 2H, CH 2 (2)), 2.81 (t, 2H, CH 2 (3), 3.03 (t, 2H, CH 2 (5)), 3.27 (t, 2H, CH 2 (4)), 3.60 (s, 7H, OCH 3 ).
[0044] Sodium hydroxide (0.83 g, 20.84 mmol) was dissolved in 80.0 mL (5.0×10 3 mmol) of deionized water, and 1.53 g (4.17 mmol) CTAB was added while stirring continuously to get a clear solution, and then compound 1 (1.24 g, 3.46 mmol) was added. The reaction mixture was stirred at ambient temperature for two hours, followed by dropwise addition of TEOS (6.97 mL, 31.27 mmol). The mixture was stirred vigorously at room temperature for two days followed by heating at 90° C. for one day to improve the structural order. The as-synthesized TPES-MCM was filtered off, and then dried at 90° C. under vacuum for 10 h. To remove the surfactant template, 3.0 g of as-synthesized TPES-MCM was refluxed for 24 hours in 9.0 mL 37.4% HCl/324.0 mL MeOH.
EXAMPLE 5
Characterization and Testing of Acidic Mesoporous Silicates
[0000] A. Characterization.
[0045] The textural properties of the mesoporous materials were measured using the BET procedure. Nitrogen adsorption-desorption isotherms were taken at 77 K using a Micromeritics ASAP 2000 system. The ion capacities of the sulfonic acid groups in the functionalized mesoporous silica were quantified using 2 M NaCl as the ion-exchange agent. Approximately 0.05 g of the sample was added to 15 ml of the salt solution and allowed to equilibrate. Thereafter, it was titrated by dropwise addition of 0.01 M NaOH (O. Margolese et al., Chem. Mater., 12, 2448 (2000).
[0000] B. Catalytic Tests
[0046] The reagents used for the catalytic test included palmitic acid (PA, ≧95%, Sigmna), refined soybean oil (SBO, Wesson) and methanol (MeOH, ≧99.9%, Fisher Scientific). A model high free fatty acid oil feed was simulated using 15% wt PA in SBO. The oil mixture was charged into the 100 ml reaction vessel with MeOH at a ratio of 1:20 w/w (PA:MeOH). The esterification reactions were performed in a stainless steel high-pressure batch reactor, Series 4565 Bench Top Mini Reactor (Parr Instrument Co., USA) fitted with mechanical stirrer and sample outlet. The reaction vessel was held at constant temperature with the aid of the heating mantle and integrated water cooling system. Catalysts were screened using different loadings (5-20% w/w of the PA). The range of reaction temperature studied was 65 to 120° C. Samples were drawn at hour intervals and their acid values were determined using the AOCS method Cd 3a-63.
[0047] Shown in FIG. 1 are the respective organosulfonic acid functional groups used in the study. The catalytic activities of the functionalized mesoporous silicas were compared with several commercial catalysts, including homogeneous catalysts (sulfuric acid and p-toluenesulfonic acid, pTSA) from Fisher Scientific and heterogeneous catalysts, Nafion NR50 (SA=0.02 m 2 /g, H + capacity=0.8 meq/g, Alfa Aesar Co. USA) and Amberlyst-15wet (SA=45 m 2 /g, Dp=250 Å, H + capacity=4.7 meq/g, Rohm and Haas Co. USA). All experiments were performed at least twice to evaluate reproducibility.
[0000] C. Results and Discussion
[0048] The textural properties of the funtionalized mesoporous silicas synthesized for the current work are summarized in Table 1, where the suffix designates the surfactant used.
TABLE 1 Textural properties S BET V P D P (Å) H + meq/g Catalyst Surfactant (m 2 g −1 ) (cm 3 g −1 ) (MPD) Sample CDAB-SO 3 H-C12 CDAB 778 0.39 28 0.60 SBA-15-SO 3 H-L64 Pluronic L64 820 0.58 27 0.84 SBA-15-SO 3 H-P123 Pluronic P123 735 0.67 35 1.44 SBA-15-ph-SO 3 H-P123 Pluronic P123 540 0.71 50 0.92
The N 2 adsorption-description isotherms of the synthesized samples had the hysteresis behavior associated with mesoporous materials (see, e.g., P. T. Tanev et al., Science, 267, 865 (1995) and M. Kruk et al., Chem. Mater., 12, 1961 (2000). The shape of the hysteresis loop indicated that the mesopores were disordered, which is a characteristic of mesoporous silica synthesized using either neutral or nonionic surfactants as templates.
[0049] As seen in Table 1, the median pore diameter (MPD) of the mesoporous materials as determined by the BJH method was dependent on the surfactant template used, which is consistent with previous reports, and can be attributed to the size of the micelle structure formed during synthesis. See, e.g., J. S. Beck et al., J. Amer. Chem. Soc., 114, 10834 (1992), J. S. Beck et al., Chem. Mater., 6, 1816 (1994). For the propylsulfonic acid functionalized samples, CDAB—SO 3 H—C16 had the smallest MPD of 21 Å (2.1 nm). The CDAB material is formed from the cooperative self-assembly of the cetyldimethy(ethyl)ammonium bromide (C 16 ), with a neutral silica precursor. This procedure yields mesoporous materials with worm-like pore structure and large wall thickness (See, H. Seong et al., Chem. Mater. ASAP, web release Oct. 3, 2003). The pore diameter of the CDAB material strongly depends on the length of the aliphatic carbon chain of the surfactant. The SBA materials were synthesized using Pluronic® L64 and P123 surfactants, which are tri-block copolymers of poly(ethylene oxide)-block-poly(propylene oxide)-block-poly(ethylene oxide), with molecular structure of EO 13 —PO 30 -EO 13 and EO 20 -PO 70 -EO 20 , respectively (J. Y. Ying et al., J. Angew. Chem. Int. Ed. Eng., 38, 56 (1999)). The SBA-15-SO 3 H—P123 sample gave the largest MPD among the propylsulfonic acid functionalized silicas. The larger MPD from use of Pluronic® P123 can be attributed to the lower EO:PO ratio of Pluronic® P123 relative to Pluronic® L64, 0.29 and 0.43, respectively. The decreased EO:PO ratio, which is a result of an increase in the molecular weight of the propylene oxide in the copolymer, increases the hydrophobicity of the resulting micelles. The increase in hydrophobilicity of the micelles will increase their size leading to an enlarged MPD in the resulting mesoporous material.
[0050] The BET surface area of the samples was in the range reported in the literature for the mesoporous materials, which validates that the solvent extraction of the surfactant was successful. No clear relation between the surface areas of the functionalized mesoporous silica and the surfactant template was observed.
[0051] The pore size distributions for the propylsulfonic acid functionalized silicas are calculated from the BJH method. The unimodal pore diameter distribution is consistent with that reported for organo-modified mesoporous silicas synthesized with either neutral or nonionic surfactants. The pore volume followed the same trend with surfactant as was observed for the MPD. There was no apparent correlation between the pore volume and the BET surface area.
[0052] The number of sulfonic acid groups in the mesoporous silica, which were determined quantitatively using acid-base titration, are given in Table 1. It is noteworthy that the acid capacity of the materials was found to increase with increasing MPD. This result was unexpected given that equal concentrations of the MPTMS and the oxidation reagent were used in the synthesis of all the samples. This difference indicates that all the sulfur must not reside in the sulfonic acid groups. It is possible the oxidation process that converts the thiol in the MPTMS precursor to the sulfonic acid group may also be oxidizing some of the adjacent thiol groups to disulfides, which would not be reactive.
[0053] The reaction performance of the functionalized mesoporous silicas was evaluated for the esterification of free fatty acids in a fatty acid/triglyceride mixture. A mixture of 15 wt % palmitic acid in soybean oil was used as the model high free fatty acid feed. This free fatty acid content is consistent with the value expected for a typical yellow grease. The transesterification of vegetable oil, which is performed with a homogeneous alkali catalyst such as sodium hydroxide or sodium methoxide, runs best using a feedstock with <0.5 wt % free fatty acid due saponification of the free fatty acid with the alkali catalyst. Transesterification of oil feeds with higher concentrations of free fatty acid leads to low yields and high production costs due to this depletion of the catalyst and subsequent formation of soap, which increases purification costs (see, U.S. Pat. No. 5,525,126). Pretreatment of a high free fatty acid oil via acid catalyzed esterification of the free fatty acid would provide a means for producing a feedstock that could be used in a standard transesterification reaction system. Therefore, the performance objective of the acid catalyst with the model feed is to decrease the palmitic acid content to less than <0.5 wt %. The esterification reaction is performed in excess methanol to favor the forward reaction, since the esterification of fatty acids with alcohol is extremely reversible.
[0054] To provide a comparison basis for the functionalized mesoporous silicas, the esterification reaction was also performed with H 2 SO 4 and two commercial acidic resins, Amberlyst-15 and Nafion. Shown in FIG. 3 are the results for reaction studies performed at 85° C. with a methanol to palmitic acid ratio of 20:1 by weight. The figure gives the palmitic acid concentration by weight as a function of reaction time. A catalyst concentration of 10 wt % was used for all of the catalysts except H 2 SO 4 , which was used at only 5 wt % concentration. As can be seen from the figure, the H 2 SO 4 homogeneous catalyst is the most active with a conversion of more than 90% in less than 1.5 hr. The high activity of H 2 SO 4 is consistent with results reported in the literature, where as low as 5 wt % loading of the cid was reported to be sufficient to esterify free fatty acids to levels of less than 0.5 wt % (B. Freedman et al., J. Amer. Oil Chem. Soc., 63, 1375 (1986).
[0055] Among the functionalized mesoporous silicas, SBA-15-SO 3 H—P123 gave the highest catalytic activity and CDAB—SO 3 H—C16 gave the least, with palmitic acid conversions of 85% and 55%, respectively, after 3 hr. The higher activity with SBA-15-SO 3 H—P123 is consistent with the material having the largest number of active sites (1.44 meq/g sample) as well as the largest pore diameter (35 Å). This observation is consistent with that reported by W. D. Bossaert et al., J. Catal., 182 156 (1999) for the esterification of gylcerol with lauric acid (dodecanoic acid) using propylsulfonic acid functionalized mesoporous silica catalysts.
[0056] As seen in FIG. 3 , Amberlyst-15 despite its high exchange capacity gave the least catalytic activity with a conversion of 40%, while the Nafion was intermediate relative to the mesoporous silica catalysts with a conversion of 70%. Amberlyst-15 is known to be an active catalyst in a number of esterification reactions and Nafion contains highly acidic sites, however, their low activity suggests that either their catalytic sites are not accessible or under the given reaction conditions they are not sufficiently reactive.
[0057] Since the superiority of the H 2 SO 4 catalyst in the reaction may be attributable to external mass transfer limitation with the solid catalysts, the esterification reaction was performed at a range of agitation speeds. Shown in FIG. 4 are the results for the SBA-15-SO 3 H—P123 catalyst, which was the most active solid catalyst. While a slight decrease in conversion was noted at the lowest stirring rate, the results for the 350 and 500 rpm runs were the same demonstrating at the higher stirring rates that were used in the current study no significant external mass transfer limitations were experienced.
[0058] Determining the cause of the higher activity for the SBA-15-SO 3 H—P123 catalyst comprises understanding of the relative importance of its higher active site concentration and its larger MPD, since both of these attributes could be contributing to the improved performance. To better evaluate these features, the reaction was performed at a range of temperatures from 65-120° C. These data were then used to calculate apparent activation energies for the catalysts. The apparent activation energies were calculated assuming a pseudo first-order reaction with respect to the palmitic acid given that methanol was present in excess and soybean oil was not significantly reacting. The linear regressions fit for the resulting values (0.95<R2<1) confirmed that the assumed first order kinetics were reasonable.
[0059] The calculated apparent activation energies are summarized in FIG. 5 for the three mesoporous silica catalysts as well as the Nafion. The apparent activation energy of the mesoporous catalysts decreased in the order of CDAB-SO 3 H—C16>SBA-15-SO 3 H-L64>SBA-15-SO 3 H—P123. It is significant to note that the apparent activation energy was found to decrease with increasing MPD. If internal diffusion was not significantly limiting the catalyst, the apparent activation energies for these catalysts should be the same since the identical sulfonic acid functional group is the active site present in all the catalysts. The importance of the sulfonic acid groups in the conversion reaction was validated by running a mesoporous silica that contained a low level of grafted propylsulfonic acid groups (0.02 meq/g). This catalyst was nearly inactive for the esterification reaction indicating that the silica has no significant esterification activity.
[0060] A likely cause of the decreased apparent activation energy with increase in MPD is the importance of activated diffusion. The impact of activated diffusion on reaction kinetics has been amply demonstrated with zeolitic catalysts in which the activation energy of diffusion is strongly dependent on temperature and follows an Arrhenius relationship. In these systems activation energies of up to 84 kJ/mol have been reported for activated diffusion (S. Bhatia, “Zeolite Catalysts: Principles and Applications,” CRL Press, FL (1990)). If the esterification reaction was limited by activated diffusion for the CDAB—SO 3 H—C16 catalyst, subsequent increase in MPD as realized with the SBA-15 catalysts would lead to decreasing reaction limitation by activated diffusion. Therefore, the results in the current study appear to support the importance of activated diffusion in the esterification of palmitic acid with mesoporous materials having a MPD at least within the range of 22-35 Å.
[0061] In addition to the accessibility of the acidic sites, a potentially important characteristic is the strength of the acid site. A more acidic catalyst was synthesized by introducing a phenyl group within the organosulfonic acid ( FIG. 1 b and FIG. 2 b ). The phenyl group, which is more electronegative than the aliphatic carbon chain, increases the acid strength of the sulfonic acid group within the catalyst. To diminish the possible effect of activated diffusion, arenesulfonic acid functionalized mesoporous silica was synthesized using Pluronic® P123, which is expected to yield a larger MPD than the other surfactants used in the study. The sample, which is denoted SBA-15-ph-SO 3 H—P123, had the textural properties and the number of active sites as given in Table 1. Despite the use of a common surfactant template, this material had a larger MPD and pore volume than the SBA-15-SO 3 H—P123 material. The difference in MPD may be attributable to the relative hydrophobicity of the arenesulfonic group relative to the propylsulfonic group. The higher hydrophobicity of the arenesulfonic group would favor a stronger intrusion of the group into the surfactant micelle causing a swelling of the micelle. This MPD result provides further evidence that the organosulfonic groups are covering the interior of the pores.
[0062] Shown in FIG. 6 is the catalytic activity of SBA-15-ph-SO 3 H—P123 for the esterification of palmitic acid relative to SBA-15-SO 3 H—P123 as well as the homogeneous catalysts H 2 SO 4 and p-toluene sulfonic acid (pTSA). SBA-15-ph-SO 3 H—P123 had significantly higher activity than SBA-15-SO 3 H—P123 despite its lower number of acidic sites. In addition, it outperformed the esterification activity of the free pTSA. While the overall conversion achieved using SBA-15-SO 3 H—P123 was similar to H 2 SO 4 , the initial reactivity of the solid catalyst was higher than for H 2 SO 4 . Esterification of free fatty acids (FFAs) with methanol releases water that is known to limit the extent of the esterification reaction. The low level of palmitic acid conversion after 60 minutes for SBA-15-SO 3 H—P123 might be due to the presence of water with water potentially having a more detrimental impact on the performance of the solid catalyst than the homogeneous catalyst.
[0063] Comparison of the reaction performance of catalysts relative to a mass-based loading of the catalysts has limitations when catalysts with different number of active sites are considered. An apparent reactivity can be defined as the average turnover rate per total number of active sites. Since internal diffusion has been demonstrated to be significant in the mesoporous catalysts, the apparent reactivity can only represent an average turnover number that is convoluted with diffusion effects. For the current catalysts the number of active sites is defined by the H + equivalents in the catalyst. Using this definition, the apparent reactivities for the catalysts at 85° C. are given in FIG. 7 . As can be seen from the figure, SBA-15-SO 3 H—P123 gave significantly higher apparent reactivity than any of the other catalysts, while the apparent reactivities for all of the propylsulfonic acid functionalized silicas as well as the Nafion were comparable. The high apparent reactivity for SBA-15-SO 3 H—P123 supports the conclusion that increasing the acidity of the sulfonic acid group enhances the reactivity of the material in the esterification reaction.
EXAMPLE 6
Transesterification of Soybean Oil
[0064] In a typical experiment, soybean oil (1.0 mL) was mixed with 5.0 mL methanol (Fisher) and the reaction was stirred at 1,000 rpm under heating at 75° C. Powdered catalyst (100.0 mg) were added to the reaction mixture. The reaction was allowed to reflux for 12 hours. The progress of the reaction was monitored by collecting aliquots every 20 minutes. The excess methanol in the aliquots was flash evaporated and the crude product was dissolved in 1 mL of CDCl 3 and analyzed by 1 H NMR spectroscopy to determine the yield of methyl soyate.
[0065] Recent catalytic studies of these alkane- and arene-sulfonic acid catalysts for transesterification of soybean oil to methyl soyate (biodiesel) showed that the presence of a phenyl group close to the sulfonic group significantly increases the acid strength in comparison to those with alkyl groups, and hence a significant enhancement of catalytic activity was observed as depicted in FIG. 8 , wherein ∇=triflic acid; O=p-toluenesulfonic acid (p-Tol-SA); □=MCM-41 silica functionalized with 4-(2-trimethoxysilyl)-ethylbenzenesulfonic acid groups (SBA-15-ph-SO 3 H—P123) MCM); Δ=MCM-41 silica functionalized with 2-[3-(trimethoxysilyl)-propyldisulfanyl]-ethanesulfonic acid (TPES) (reaction temperature 75° C.).
[0066] In contrast to the high catalytic activity of the SBA-15-ph-SO 3 H—P123 material, arenesulfonic acid-functionalized MCM-41 silica catalyst prepared by the postsynthesis grafting method gives rise to imhomogeneous surface coverage of the catalytic sulfonic acid groups and hence lower catalytic activity (three fold decrease relative to that of the P123 material). Such an inhomogeneous surface coverage of catalytic groups apparently inhibit or slow down the diffusion of both the reactants and products from accessing/leaving the catalytic sites. The results indicated that the ability of control and fine tune the location and surface density of the sulfonic acid catalytic groups is a crucial prerequisite for efficient conversion of the desired products. Also, the feasibility of tuning the acid strength of the sulfonic groups by close attachment of different functionalities might increase their potential catalytic applications. Therefore, the present synthetic methods can also be used to introduce various acid groups, such as maleic acid and perfluorosulfonic acid [Si(OCH 3 ) 3 (CF 2 ) 2 SO 3 H], to the mesoporous silica surface to generate solid catalysts with different acid strengths for selective transesterification of soybean oil.
[0067] All publications, patents and patent applications are incorporated herein by reference. While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purposes of illustration it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein may be varied considerably without departing from the basic principles of the invention. | The present invention provides a method to prepare a fatty acid lower alkyl esters from a feedstock, such as a vegetable or an animal oil, comprising one or more fatty acid glycerol esters such as mono-, di- or tri-glycerides, and free fatty acids, comprising combining the feedstock, a lower alcohol and an acidic mesoporous silicate under conditions wherein the mesoporous silicate catalyzes the formation of the corresponding fatty acid lower alkyl ester of the free fatty acids an optionally glycerol. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of my prior patent application Ser. No. 469,819, filed May 14, 1974 as a continuation-in-part of my prior patent application Ser. No. 290,223, filed Sept. 18, 1972 and both now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to scrubbing of chlorine. More particularly, it relates to catalytic decomposition of hypochlorite formed by scrubbing of chlorine-containing gas.
2. Description of the Prior Art
Scrubbing of chlorine-containing gases with alkali or alkaline earth metal hydroxide solution eliminates discharge to the atmosphere of most of the chlorine. However, the principal product of such scrubbing, hypochlorite, is often present in sufficiently high concentration to contaminate or pollute and create an objectionable odor in the streams or ponds of water receiving it.
It has previously been proposed to decompose such hypochlorites by exposing them to metal oxides such as the oxides of cobalt, copper, nickel or the like.
Kriegsheim U.S. Pat. No. 1,153,502 suggests, however, that the speed and completeness of the action depends very materially on the physical form of the oxide and upon the circumstances such as upon the way in which the reaction mixture and the catalyst are brought together. Kriegsheim, therefore, suggested that the salts of cobalt and other metals should be reacted with a zeolite, apparently to form a compound catalyst. Whether this compound catalyst included the metal as a salt or in oxide form is unclear.
Vasilev and Mikhaylova in KINETICS OF CATALYTIC DECOMPOSITION OF SODIUM HYPOCHLORITE (Kum vuprosa za kinetikata na katalitichnoto razlagane na natriev khipokhlorit.) Godishnik na Khimiko- Tekhologicheskiya Institut, Vol. 10, No. 2, pp. 25-32, 1963, discussed the use of copper, cobalt and nickel catalysts using chloride salts of these metals. They concluded that cobalt was the most effective catalyst. However, conversion of the amount of catalyst used (1 gram-mole per liter) to ppm indicates that a huge amount of catalyst (over 56,000 ppm) was used which would, of course, be economically unattractive. The recital of the amount of other ingredients indicated that Vasilev et al were operating in a pH range of about 13.2. SUMMARY OF THE INVENTION
After extended investigation, I have found that the problems outlined above can be substantially eliminated by catalytic decomposition of the hypochlorite into basically non-polluting products, chloride of the alkali metal or alkaline earth metal and oxygen. To do this, I employ, as catalyst a material containing one or more of the elements cobalt, nickel, copper and calcium, while operating in a pH range of 7-13. The catalyst concentration is at least 9 ppm and most advantageously is between 9-1000 ppm. Representative materials for supplying the catalyst, which appears to be converted to the oxide form in the course of the decomposition of the hypochlorite, include (1) salts (nonoxides) such as the nitrates and chlorides, for example, the hydrated form Co(NO 3 ) 2 .6H 2 O for cobalt (the most effective catalyst according to the invention), (2) the fused metal, and (3) the metal powder, although decomposition rates are generally slower for the catalyst in elemental form.
BRIEF DESCRIPTION OF THE DRAWING
The sole drawing comprises a diagrammatic outline of the process of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For a better understanding of the invention reference will now be made to the drawing which forms a part hereof.
In the drawing, chlorine-containing gas enters scrubber 10 via line 12 and is scrubbed by sodium hydroxide solution, which enters at line 14. Effluent from scrubber 10 containing sodium hydroxide, sodium carbonate and sodium hypochlorite is conducted at a pH of 8.5 via line 16 to baffled decomposition tank 18, which is maintained at a temperature of 60°C. Catalytic cobaltous nitrate hexahydrate supplied from source 20 enters the scrubber effluent via line 22. Steam enters tank 18 at line 24. During about 6 hours of residence time in decomposition tank 18, the sodium hypochlorite, with the aid of the cobalt catalyst, is broken down into oxygen, which exits at line 26 and is discharged to stack 28, and sodium chloride, which exits at line 30 in an effluent also containing sodium carbonate, the excess sodium hydroxide from the scrubbing operation and insoluble cobalt oxide (CoO).
The hypochlorite treated according to my invention is formed by scrubbing of chlorine-containing gas with a base, for example, alkali or alkaline earth metal compound such as hydroxide or carbonate. When I refer to chlorine-containing gas, I include phosgene and any other gas containing chlorine alone or combined which produces hypochlorite upon alkaline treatment. There may also be some alkali or alkaline earth metal carbonate-which comes from the carbon dioxide in the chlorine-containing gas being scrubbed-in the scrubbing product containing the hypochlorite to be decomposed according to the invention. Such carbonate is usually substantially unaffected by the catalytic treatment of the hypochlorite. Thus, the principal or primary reaction taking place during the decomposition procedure employed according to my invention may be represented by the net overall equation,
2NaOCl → 2NaCl + O.sub.2 ↑,
the resulting products being substantially non-polluting.
I have determined that the rate of decomposition of the hypochlorite when a cobalt catalyst is used may be calculated from the equations,
log r = 0.0324T + 1.3703 log Z - 0.16699 pH--4.6162
and
r = log N.sub.o - log N.sub.F,/t
wherein r is the rate constant of decomposition, T the temperature in degrees Centigrade (°C), Z the cobalt catalyst concentration (expressed as the element) in parts per million by weight (ppm), N o the initial NaOCl concentration in grams per liter (g/1), N F the final NaOCl concentration in g/1 and t the time of residence in the tank in minutes. Preferred catalyst concentration is at least about 9 ppm, most advantageously between 9 and 1000 ppm. Representative materials for supplying the catalyst, which appears to be converted to the oxide form in the course of the decomposition of the hypochlorite, include salts such as the nitrates and chlorides, for example, the hydrated form Co(NO 3 ) 2 .6H 2 O for cobalt (the most effective catalyst according to the invention), the fused metal and the metal powder, although decomposition rates are generally slower for the catalyst in elemental form. Thus, the use of the term "salts" as well as the terms "fused metal" and "metal powder" are intended to exclude metal oxides.
The pH may be adjusted for optimum decomposition and is preferably held at 7-13, since at a pH below 7 the hypochlorite may decompose spontaneously and release free chlorine gas, and at a pH above 13 the hypochlorite becomes stabilized, requiring unduly high amounts of catalyst. The optimum temperature range for conducting the hypochlorite decomposition according to the invention is 20°-80°C, 45°-75°C being preferred, although the solution to be treated may reach its boiling point without any adverse effect.
While the process of the invention may be conducted batchwise, I prefer to decompose the hypochlorite by passing it substantially continuously through a baffled vessel in the presence of the catalyst via a circuitous route.
The following examples are illustrative of the invention.
EXAMPLE 1
A solution containing sodium hypochlorite was prepared by scrubbing chlorine with sodium hydroxide, the solution also containing Na 2 CO 3 from the reaction of CO 2 with the NaOH, and a small excess of NaOH. The pH of the solution was controlled to be between 8 and 9. The relative rates of decomposition of such solution with various cobalt-supplying catalysts are shown in Table I, using for comparison a rate of (1) for a single piece of cobalt. In the run employing the cobalt nitrate hexahydrate catalyst, a finely divided cobalt oxide (CoO) precipitated
Table I______________________________________Relative Rates of Decomposition of NaOCl 27°C 50°CCo Additions 600 ppm Co 50 ppm Co______________________________________Co(NO.sub.3).sub.2.6H.sub.2 O (crystals) 2.9 3.6Co Powder < 325 mesh 2.0 2.0Co (single spherical piece) 1.0 1.0______________________________________
EXAMPLE 2
Waste sodium hypochlorite from alkaline scrubbing of chlorine was decomposed into NaCl and O 2 in a series of runs, varying the conditions of operation as they appear in the following table.
Table II______________________________________Inlet Outlet ResidenceNaOCl, NaOCl, Temp., Time Co,g/l g/l °C pH min. ppm______________________________________ 3.3 0.08 43 7.3 900 18-2193.4 0.7 90 11.6 450 980.0 2.0 80 11.6 500 12______________________________________
EXAMPLE 3
A system for decomposing hypochlorite to chloride and oxygen similar to that of the drawing was operated continuously for several days, decomposing approximately 10 gallons per minute of an 85 g/l sodium hypochlorite solution resulting from scrubbing chlorine with sodium hydroxide.
EXAMPLE 4
The addition of 45 ppm cobalt from cobaltous nitrate hexahydrate, [Co(NO 3 ) 2 .6H 2 O] to a solution coming from a scrubber in which chlorine-containing gas was scrubbed with sodium hydroxide, the solution containing 85 g/l sodium hypochlorite and being at a pH of 8.5 and a temperature of 47°C, resulted in catalytic decomposition of the hypochlorite to sodium chloride and oxygen in 6 hours. The initial hypochlorite concentration was determined by iodometric titration. The rate of sodium hypochlorite decomposition was determined by measuring gas evolution as a function of time in a water displacement apparatus. Displacement was recorded periodically from burette readings and temperature read with a thermometer suspended in the solution. The solution was stirred continuously with a magnetic stirrer. The volume of gas displaced was the difference between the initial and final burette reading, each milliliter of the burette reading being equivalent to 0.2 g NaOCl per liter. The volume of oxygen evolved was determined, assuming ideal behavior for the gas. After calculation of moles of oxygen released, the amount of sodium hypochlorite which should remain after decomposition was determined from the equation NaOCl → NaCl + 1/2 O 2 . This value was then subtracted from the initial hypochlorite concentration and found to be substantially the same as the comparative value obtained by iodometric titration of the final solution. The volume of collected gas also agreed quantitatively with the measured titration value. Mass spectrographic analysis showed that the collected gas formed by the catalytic decomposition of the hypochlorite was oxygen.
EXAMPLE 5
A comparison was made of the relative activities of cobalt, nickel, copper and calcium catalysts in decomposing sodium hypochlorite obtained by alkaline scrubbing of chlorine into sodium chloride and oxygen. Relative activities were found to be 115, 40, 10 and 1 respectively, using the 1 for the reference or comparison point.
EXAMPLE 6
To further compare the process of the invention to the use of compound catalysts using zeolite supports as suggested by the prior art several runs were made using, in each instance 70 ppm cobalt. A standard NaOCl solution was prepared by adding 40 grams of NaOH to 1000 cc of H 2 O and mixing until dissolved. Cl 2 was then bubbled through the solution while monitoring the pH. The Cl 2 was then shut off and N 2 bubbled through the solution for 1/2 hour. The final pH reading was 10.
For run A (corresponding to the process of the invention) 0.011 grams of Co(NO 3 ) 2 .6H 2 O was added to 30 cc of the above NaOCl solution at 58°C. The evolved gas (O 2 ) was measured every 5 minutes using an inverted burette until evolution stopped.
For run B, 0.046 grams of an impregnated zeolite containing 70 ppm cobalt was substituted for the cobaltous nitrate of run A. The impregnated zeolite was prepared by adding 100 grams of cobaltous nitrate [Co(NO 3 ) 2 .6H 2 O] to 200 cc of H 2 O. After the cobaltous nitrate had dissolved, 10 grams of a zeolite mixture CS-207-V (Fisher Scientific) was added and the mixture stirred for 1 hour to saturate the zeolite with the cobaltous nitrate solution. The mixture was then filtered and the impregnated zeolite was placed in an oven to dry overnight at 110°C.
From previous experimentation, it has been determined that Co(NO 3 ) 2 .6H 2 O, when heated to 250°F (about 120°C) converts to Co(NO 3 ) 2 .3H 2 O. Using this computation, 0.046 grams of the impregnated zeolite (including the tare weight of the zeolite) was calculated to provide 70 ppm cobalt as in run A. This amount of impregnated zeolite was then placed in 30 cc of the above NaOCl solution at 58°C and the evolution of gas again measured as in run A.
In run C, 0.031 grams of a zeolite impregnated as described above was used. This zeolite, however, was previously heated to 1500°F to convert the impregnated Co(NO 3 ) 2 .6H 2 O to CoO. The 0.031 gram amount was calculated to provide 70 ppm cobalt as in runs A and B (including the tare weight of the zeolite).
This impregnated zeolite was added to 30 cc of the above 58°C NaCl solution and the evolution of gas again measured.
The results for runs A, B, and C are all tabulated below.
Table III______________________________________Time in minutes Evolved Gas in ml. Run A Run B Run C______________________________________5 60 5010 116 9315 158 12720 188 15025 200 16430 202 17635 203 18440 204 18645 204*505560 19185 195135 204145 73180 204*190 92225 103265 108300 114330 117380 125395 125*______________________________________ *Test Stopped
The results clearly indicate that there is no benefit and actually some detriment in using the compound catalyst utilizing zeolite carriers as taught in the prior art. Furthermore, as seen in run C, introduction of the cobalt initially in oxide form provides inferior results compared to the introduction of the cobalt as a salt, as that term has been defined hereinabove.
While I do not wish to be bound by any theory, it seems that possibly the introduction of the cobalt catalyst into the NaOCl solution as a salt or in elemental form results in a precipitate of cobalt oxide with enhanced catalytic properties compared to the use of cobalt already oxidized. This may be due to a more finely divided cobalt oxide being precipitated from the NaOCl solution.
In any event, it can be clearly seen that the use of an unsupported catalyst in accordance with the invention in run A resulted in complete reaction in less than 1 hour while the use of supported catalysts in salt or oxide form as in runs B and C respectively resulted in longer reaction times which--in the oxide case--was over 6 hours with incomplete reaction.
While the invention has been described in terms of preferred embodiments, the claims appended hereto are intended to encompass all embodiments which fall within the spirit of the invention. | Use of Co, Ni, Cu or Ca catalyst to decompose hypochlorite contained in the product resulting from scrubbing of chlorine-containing gas. | 2 |
This is a continuation of application Ser. No. 08/408,268 filed Mar. 21, 1995, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to computer systems and, more particularly, to a RAMDAC (random access memory-digital-to-analog converter) used to transfer and process data from a frame buffer to an output display device.
2. History of the Prior Art
One of the significant problems involved in increasing the operational speed of desktop computers has been in finding ways to increase the rate at which information is transferred to an output display device. Many of the various forms of data presentation which are presently available require that large amounts of data be transferred. For example, if a computer output display monitor is operating in a color mode in which 1280×1024 pixels are displayed on the screen at once and the mode is one in which thirty-two bits are used to define each pixel, then a total of over forty million bits of information must be transferred to the screen with each individual picture (called a "frame" that is displayed. Typically, sixty frames are displayed each second so that over one and one-half billion bits must be transferred each second in such a system. This requires a very substantial amount of processing power.
In order to provide such a large amount of information to an output display device, computer systems typically utilize a frame buffer which holds the pixel data which is to be displayed on the output display.
Typically a frame buffer offers a sufficient amount of random access memory to store one frame of data to be displayed. The information in the frame buffer is transferred to the display from the frame buffer sixty or more times each second. After (or during) each transfer, the pixel data in the frame buffer is updated with the new information to be displayed in the next frame.
In DRAM frame buffers, pixel data may be read from the same port as data is written. VRAM frame buffers add a separate video data port so that the main pixel port remains free for rendering. Two-ported video random access memory (VRAM) or frame buffer random access memory (FBRAM) has been substituted for dynamic random access memory (DRAM) so that information may be transferred from the frame buffer to the display at the same time other information is being loaded into the frame buffer.
The data from the frame buffer is input to circuitry which converts the data from the frame buffer to a form usable by the output display device. FIG. 1 shows a computer system in which the present invention may be utilized where data in a memory 11 from a host CPU 12 is placed on host bus 13 and passed by rendering converter 14 to the frame buffer shown in FIG. 1 as VRAMs 15a-15d although FBRAMs may also be used. A RAMDAC 21 is coupled to the host bus through the rendering controller and to the frame buffer and includes a look-up table (or LUT which is the RAM part of the RAMDAC) and other elements for translating 16 bit data from the frame buffer to a 64 or 128 bit digital RGB signal which is converted by a digital to analog converter (DAC) to three analog signals representing voltage levels for red, blue and green which when combined at a pixel location in monitor 25 create a desired color at that pixel. The particulars of the frame buffer memory, rendering controller and monitor components are well known in the art and will not be described herein except as necessary for a proper understanding of the invention. In this connection, for the most part, the present invention is directed to certain improvements to RAMDAC 21 which provide the enhanced capabilities of the invention.
SUMMARY OF THE INVENTION
For certain applications including stereo display, virtual reality and video recording, it is required to synchronize the vertical blanking of multiple frame buffers. The frame buffers may exist on the same computer or separate computers.
A similar, but much more complex synchronization problem has been encountered and solved in television studios. There, it is necessary to cause cameras, encoders, special effects generators recorders and modulators to operate synchronously. A master generator provides the timing and frequency references, often referred to as Genlock, for the entire arrangement of equipment. However, generating a Genlock signal requires video sync filtering and acquisition hardware, which can add cost to a system.
All frame buffers in a group to be synchronized contain their own video timing generators. All are programmed to use the same video timing. Variations in the reference frequencies used by each frame buffer will eventually cause the frame buffer's video timing to drift relative to another frame buffer. Furthermore, without a mechanism for synchronizing the vertical sync event all frame buffers will have this event offset in time.
With this invention, one frame buffer is the master. It provides a signal called FIELD that changes state (0 to 1 or 1 to 0) at the start of every vertical sync event on the master frame buffer. All other frame buffers are set to be slaves. Their timing generators sample the master's FIELD signal. When they detect the master's FIELD signal changing state, they set their own internal timing to match. As implemented, all frame buffers use the transition of an internal counter from a nonzero value to zero as the vertical sync event. Slave frame buffers set their vertical counters to zero, and their internal field signal's state to that of the master's, when they detect a change in the master's field signal.
This provides a very inexpensive technique of achieving frame synchronization. Although it may not be as precise as Genlock, it is much simpler to implement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block overview diagram showing a system in which the RAMDAC of the present invention may be utilized.
FIG. 2 is a block overview diagram showing three systems which operate in synchronism with each other utilizing the present invention
FIG. 3 is a detailed block diagram of a RAMDAC,
FIG. 4 shows timing generation for non-interlaced format.
FIG. 5 shows horizontal timing and composite sync generation for non-interlaced format.
FIG. 6 shows horizontal timing waveforms for interlaced format.
FIG. 7 shows NTSC video timing.
FIG. 8 is a block overview diagram of the video timing generator of the present invention.
FIG. 9 is a detailed block diagram of the video timing generator of the present invention.
FIG. 10 is a logic gate implementation of the video timing generator of the present invention.
FIG. 11 is a detailed block diagram showing the operation of equality comparators.
FIG. 12 shows field generator master mode timing.
FIG. 13 shows field generator slave mode timing.
DETAILED DESCRIPTION OF THE INVENTION
A system utilizing two or more video monitors displaying related or contiguous images generated by two or more computers may exhibit aberrations in the viewed images because the computers do not operate from a single timing reference. The present invention provides a simple, low cost technique for sharply reducing such aberrations in the viewed images.
FIG. 2 represents a hypothetical arrangement having three systems; the number of systems may be increased or decreased without effect on the principle under discussion. Each of these systems includes a a monitor or other video display 25 RAMDAC 21, a graphics engine, or other video data source such as rendering controller 14, a frame buffer memory 15 and host computer 12. Components other than the RAMDAC, are included as an example of an implementation of the RAMDAC in a complete system. At the top of the illustration is a box labeled VIEWER which represents a person who observes the visual data presented on the three video displays.
One key feature of this arrangement is the nature of the displayed video data. The data are related to one another, so that all three displays are required to represent a complete scene. Also important is the fact that the displayed data are not static, they convey the impression of movement. For example, such an arrangement might be used as part of a flight simulator, wherein video display 2 provides the forward view from the simulator cockpit and video displays 1 and 3 provides the left and right views. Each of these displays may be stereoscopic displays, which impart a greater sense of "reality" to the simulation. In this case, each of the video displays must alternately and synchronously present left eye views and right eye views. The viewer wears special goggles which act as shutters for each eye, alternately and synchronously admitting left data to the left eye and right data to the right eye. The need for synchronization is clearly necessary, but synchronization is not a natural consequence of placing three video displays side by side as shown in FIG. 2. There are several reasons for this, all of them having to do with the clocks which regulate the rate at which processes occur in the RAMDAC, graphics engine and the host CPU and the quantity of data rendered by the graphics engine into the frame buffer.
Consider a single system, i.e., one of the three shown in FIG. 2. It is impractical to require all of the components of such a system to operate at one clock frequency. The CPU and the graphics engine are each designed to operate at the greatest possible clock frequency, but these frequencies may differ. The RAMDAC is required to operate at several frequencies, each of which is related to certain fundamental units of time, the pixel periods, defined by various video display formats. Consequently, the rate at which video data are rendered is not related to the rate at which video data must be displayed. This difference is reconciled by the frame buffer which accepts rendered data from the graphics engine at one rate and delivers these data to the RAMDAC at a different, usually faster, rate. This works well if the displayed data produce an image which is static. If motion (animation) is required, a larger frame buffer is needed. This large buffer is divided into two parts, referred to for convenience as buffers A and B. Each of these buffers is connected to the graphics engine and to the RAMDAC. This double buffering scheme works in this way. The first view of an animated sequence is rendered into buffer A. When the rendering is completed, the RAMDAC is told, by a control mechanism synchronized to the vertical blanking point of the video timing generator, to display data from buffer A. Once this is done, the CPU and the graphics engine begin rendering data for the next view into buffer B. When rendering is completed, the roles (rendering and display) of buffers A and B are again reversed. This process continues, resulting in the illusion of smooth motion (provided the rendering rate is sufficiently high) without noticeable aberrations. The point at which the buffer switching occurs is triggered by the completion of rendering and by the arrival of the subsequent video vertical blanking interval. The latter event is produced by the timing generator circuits of the RAMDAC and its external manifestation is a signal called the FIELD signal. A transition of the FIELD signal indicates that a new frame of video (a frame is one complete image) is about to start. In the implementation described herein, the direction of the FIELD signal transition, for non-interlace monoscopic displays, is irrelevant. However, the direction of the transition is very important for stereoscopic and interlaced displays. In the former case, the level of the FIELD signal indicates which of the stereoscopic views, left or right, is to be processed and displayed by the RAMDAC, video display and stereoscopic goggles, if present. In the latter case, the level of the FIELD signal identifies the current field as either the odd field or the even field.
When used in stereoscopic mode, the double buffered frame buffer is reorganized. Buffers A and B are retained but each one is again divided into two buffers. One of these holds data belonging to the left eye view and the other holds data belonging to the right eye view. The previously described rendering and display operations also apply in the stereoscopic mode.
FIG. 2 shows three systems which must display related or contiguous video data. Therefore, it is necessary for all systems to know when rendering of a particular video frame has been completed so that all systems can trigger the buffer switching operation at the same time. The time required for each system to complete its portion of the rendering task depends, in large part, on the contents of the scene being rendered. These contents will differ among the three systems. Consequently, the completion times will differ. Software and a local area network 17 are used to monitor the progress of rendering in the three systems. Once all systems have completed their rendering tasks, the buffer switching operation is triggered via the local area network. This facility solves one aspect of the synchronization problem. Another problem exists resulting from the fact that the timing references (clocks) for the three RAMDACs are independent of one another. Although the trigger for the buffer switching operation can be made to occur virtually simultaneously, the simultaneous transition of the three FIELD signals cannot be guaranteed by the described circuitry.
Each of the three RAMDACs receives clock signals generated by three independent, crystal controlled oscillators (not shown in FIG. 2) operating at a single nominal frequency. The actual frequencies produced by these oscillators will vary within a range of values (tolerance) which depends on the tolerance of the crystal resonator and local conditions such as temperature and, to some extent, voltage. In principle and practice it is not possible to guarantee that two, or more, such oscillators will produce the same frequency over an extended period of time. For example, assume three such oscillators connected not to video displays but to three counter circuits used by three watches. If all three systems were to be turned on at the same instant and the clocks compared after a few hours of operation, the indicated times would be different and the differences would grow over time. The same phenomenon will occur in the above-described hypothetical system shown in FIG. 2. Given sufficient time, the three systems will enter the video vertical blanking interval, as indicated by the FIELD signal, at different times. Should this occur in monoscopic systems, the disruption will be noticeable. In stereoscopic systems the effect will be dramatic since left and right eye views will not be coherent across the three systems.
The solution provided by the present invention does not seek to synchronize the three oscillators. Rather, it synchronizes events produced in the video timing generator circuits of the three RAMDACs (which are referenced to the oscillators). This approach exploits the fact that differences between the oscillators will be small if measured over a small interval of time. The period between successive FIELD signals is such a short interval (the period varies as a function of the particular video format, it is a maximum of 20 milliseconds and a minimum of about 13 milliseconds for the video formats supported in a typical implementation). In the illustrated hypothetical arrangement, system 1 is programmed to act as the master and systems 2 and 3 are programmed to act as slaves. As the arrowheads in the illustration indicate, the master system emits the FIELD signal and the slave systems receive it. Thus, system 1 becomes the source of the vertical interval timing reference and, in the stereoscopic mode, the controlling signal for stereoscopic goggles. The slaves respond to the received FIELD signal by resetting the counters (horizontal and vertical dimensions) which produce the video timing signals such as horizontal synch, vertical synch, and blanking The reset state is defined to be identical to the state which exists in the master RAMDAC at the time when it emits the transition in the FIELD signal, thus achieving the required synchronization. If the three systems are observed, it would be discovered that vertical blanking (or start of frame) occurs nearly simultaneously. The differences in the times at which these events occur are caused by delays incurred in the interconnecting cables and in the moment at which the counters are actually reset. These differences are very small (on the order of microseconds) and cannot be perceived by the viewer. The present invention lies in this method of achieving synchronization and the circuit elements utilized.
FIG. 3 illustrates the components of a RAMDAC 21 which can be utilized to implement the present invention. The RAMDAC includes several functional blocks as follows: CPU port, interface logic, address pointers and data registers 31, pixel port, pixel input registers and serialization 33, shadow and RAM look-up tables, transfer control and overlay, underlay logic 35, color model selection 37, cursor logic serialization 39, monitor serial port 41, diagnostic registers and control logic 43, digital-analog converters (DAC) 45a-45c and PLL clock synthesizer, pixel clock divider and video timing generator 49. The invention lies mainly in an implementation of the video timing generator component of PLL clock synthesizer, pixel clock divider and video timing generator 49 which generates a FIELD signal for use by other RAMDACs as described above to provide synchronization. Therefore, the following description will be limited to the video timing generator, with information pertaining to the other components of the RAMDAC provided only as needed for an understanding of the present invention. Although the other components shown in FIG. 3 may vary between RAMDACs of different manufacturers, persons skilled in the relevant art will recognize these various components and know how they or their equivalents may be implemented
Frame buffer data is provided to the pixel port as pixel port signals such that the pixel inputs are divided into two ports, labeled A and B which consist of four groups per port. Furthermore, each group is divided into an upper byte and a lower byte. Thus, the pixel port comprises a total of 128 pixel bits contained in groups 0 through 7. Table 1 illustrates these assignments.
TABLE 1______________________________________Pixel Port Naming ConventionPixel Port Group Group Bits Device Bits______________________________________B 7 15:8! PB(63-56) 7:0! PB(55-48) 6 15:8! PB(47-40) 7:0! PB(39-32) 5 15:8! PB(31-24) 7:0! PB(23-16) 4 15:8! PB(15-08) 7:0! PB(07-00)A 3 15:8! PA(63-56) 7:0! PA(55-48) 2 15:8! PA(47-40) 7:0! PA(39-32) 1 15:8! PA(31-24) 7:0! PA(23-16) 0 15:8! PA(15-08) 7:0! PA(07-00)______________________________________
However, the specifics of the manner in which the frame buffer pixel data is provided to the pixel port of the RAMDAC may vary and is not critical to an understanding of the invention.
Video Timing Generator
The present invention utilizes a programmable timing generator, operating from a serial clock, and providing video display and video memory timing reference signals.
The timing generator produces signals which are described below. The timing generator operates in two dimensions, specifically, horizontal, corresponding to the horizontal scan of a video display format, and vertical, corresponding to the vertical scan of a video display format. Events in the horizontal dimension, such as horizontal synch, are placed on boundaries defined by the serial clock period. Events in the vertical dimension, such as vertical sync, are placed on boundaries defined by a whole number of horizontal scans in the case of non-interlaced displays, or by half horizontal scans in the case of interlaced displays. The number of serial clock periods within a horizontal scan is variable and the number of horizontal scans within a video frame is variable. The design of the timing generator provides that when generator outputs are observed at the outputs of the RAMDAC, they are correctly placed relative to the video data being input to the pixel port. For example, if the generator is programmed to assert some event congruent to pixel number p, then it will be seen, at the RAMDAC output, to occur at a position corresponding to pixel number p. The timing generator incorporates a rudimentary frame synchronization feature as described below. Finally, the timing generator incorporates a timing generator control register having control register bit definitions which are shown in Table 2, "Timing Generator Control Register," below. This register is read from and written to under control of host CPU 12 through the CPU port and interface logic which are coupled to multiplexed data/address bus D 07:00!.
TABLE 2__________________________________________________________________________Timing Generator Control Register ResetBit Field R/W Value Description__________________________________________________________________________0 Video Enable R/W 0 Upon reset or writing a zero to this bit causes the DAC (0) Disabled outputs to be blanked. Any signature acquired during video (1) Enabled disable state will have pixel data set to be zero.1 Timing Generator Enable R/W 0 Writing a one to this bit causes the timing generator to (0) Disabled restart at the beginning of the upper left corner of an even (1) Enabled frame. This change is effective at time next rising edge of the internal timing generator clock. Upon reset or writing a zero causes both horizontal and vertical counters to be disabled2 Horizontal Sync Disable R/W 0 Upon reset or writing a zero causes the signals HSYNC* and (0) HSYNC Enabled CSYNC* to be enabled. Writing a zero disables the (1) HSYNC Disabled horizontal component of both signals3 Vertical Sync Disable R/W 0 Upon reset or writing a zero causes the signals VSYNC* and (0) VSYNC Enabled CSYNC* to be enabled. Writing a zero disables the vertical (1) VSYNC Disabled component of both signals4 Equalization Disable R/W 0 Equalization pulses happen if the chip is in interlaced mode (0) Equalize Enabled and this bit is set to zero. Otherwise CSYNC should look (1) Equalize Disabled like the non-interlaced case: horizontal syncs occur on CSYNC except during vertical sync; during vertical sync CSYNC has serration pulses.5 Master Mode R/W 0 This bit controls the direction of the FIELD I/O signal. (0) Slave When this bit is a logical zero, the RAMDAC uses the (1) Master externally-provided FIELD signal to start at the top of a new frame.6 Interlaced Mode R/W 0 This field selects the mode of operation of the timing (0) Non-Interlaced Mode generator. A logical one causes the timing generator to (1) Interlaced Mode operate in interlaced mode.7 Reserved__________________________________________________________________________
Frame Synchronization
The timing generator enables video frame synchronization of several displays. The timing generator is capable of operating either as a master or a slave as specified by bit 5 of the timing generator control register.
When the timing generator is operated as a master, the FIELD signal is an output producing the periodic functions described in Table 3, "Timing Generator Signal Description," below.
When the timing generator is operated as a slave the FIELD signal is an input which serves to set the horizontal and vertical elements of the generator so that they correspond to the start of vertical synch. Timing generators operated in the slave mode will not drive the FIELD signal. A further description of slave mode operation is described below.
System Reset
When asserted, the system reset signal, RS*, causes three effects as follows.
Video Enable (bit 0 of the timing generator control register) is forced to the disabled state by the assertion of system reset. This condition persists after the negation of system reset and stays in the disabled state until it is overwritten via the CPU port. Video Enable, when in the disabled state (i.e,, reset), asserts composite blanking within the RAMDAC so that the video monitor remains black while the timing generator is being programmed to prevent random patterns or flashing from appearing on the display during, for example, a system boot when configuration and control data are being loaded into the timing generator.
When asserted, system reset forces the timing generator to assume a known state as follows. Timing Generator Enable (bit 1 of the timing generator control register) is forced to the disabled state by the assertion of system reset. This condition persists after the negation of system reset and stays in the disabled state until it is overwritten via the CPU Port. The purpose is to hold the timing generator in a known state while it is being programmed so that random FIELD, SC and SCen signals are not presented to other components of the system during such programming.
When asserted, system reset causes the timing generator to be in the slave mode. The FIELD signal is placed in a high impedance mode when the timing generator is in the slave mode.
Timing Generator Signals
The timing generator signals are described in Table 3, "Timing Generator Signal Description," below.
TABLE 3__________________________________________________________________________Timing Generator Signal DescriptionSignal Name Description__________________________________________________________________________CSYNC* Composite Synch. This signal is conveyed to the video monitor as a discreet signal or, optionally, it is added to the Green channel DAC in the usual manner. The "synch on green" and other composite synch options are controlled by register programming. Composite Synch is the video synchronization signal and comprises horizontal and vertical, optionally serrated, synch components. For interlaced formats, such as NTSC and PAL, these components include horizontal equalization pulses.STSCAN A pixel port output. External circuitry interprets this signal as "start of each visible horizontal scan line" and uses it to index the video memory.FIELD A pixel port bidirectional signal. FIELD is an input when the synch generator is operated in the slave mode; it is an output when the generator is operated in the master mode. In interlaced formats, FIELD differentiates odd and even fields. In non-interlaced sequential display formats, FIELD simply indicates the start of the frame. External circuitry uses FIELD to index the video memory and, to control LCD shutters used in stereographic viewing. FIELD changes state congruent to vertical synch.SCen* A pixel port output. Serial Clock enable is used by external circuitry to regulate the extraction of data from the serial port of the video memory. Assertion and negation of this signal are controlled by programmable registers in the horizontal SCen H Negation point, and SCen H Assertion point. SCen is active on unblanked lines as defined by VBlank Negation point and VBlank Assertion point.__________________________________________________________________________
Timing Generator Display Formats
The timing generator is controlled by programming the appropriate values into the timing generator control registers. These registers are listed in Table 4, "Configuration Functions," below.
TABLE 4______________________________________Configuration Functions______________________________________Video Format Control RegisterPLL Control RegisterTransparent Overlay Mask RegisterTransparent Overlay Color Key RegisterWindow Attribute - Active LUTWindow Attribute - Shadow LUTColor LUTTiming Generator Control RegisterV-blank. Negation Point RegisterV-blank. Assertion Point RegisterV-sync. Negation Point RegisterV-sync. Assertion Point RegisterH-serration. Negation Point RegisterH-blank. Negation Point RegisterH-blank. Assertion Point RegisterH-sync. Negation Point RegisterH-sync. Assertion Point RegisterHSCen, Negation Point RegisterHSCen, Assertion Point RegisterEqualization Pulse Negation Point Reg.Equalization Interval Negation Point Reg.Equalization Interval Assertion Point Reg.Vertical Counter (R/O)Horizontal Counter (R/O)Device Identification RegisterSignature Analysis RegisterMonitor Serial Interface DATA RegisterMonitor Serial Interface CNTL RegisterDAC Control RegisterWindow Transfer Control Register______________________________________
Both interlaced and non-interlaced modes of operation are supported. All horizontal register values are in units of the serial clock rate. All vertical register values are in units of the horizontal lines. In a typical embodiment, the values to load into a register is one less than the desired count or duration. The programming of these modes is described in the following paragraphs.
Non-Interlaced Mode
In addition to serrated sync support for interlaced mode, the RAMDAC also supports the generation of serrated sync for non-interlaced mode. The composite sync is derived by using horizontal sync outside of the vertical sync interval, and using the serrated sync waveform during vertical sync interval. This is graphically depicted in FIG. 4, "Timing Generation-Non-Interlaced Format" with reference to the following description.
Horizontal Timing Generation
For generating the horizontal and serrated sync signals, the HSAP (horizontal sync assertion point), HSNP (horizontal sync negation point), and HSERNP (horizontal serration negation point) registers are programmed with the desired durations, in SC* clock units (serial clock described below). All the parameters should be programmed as one less than the desired duration.
The operation may be described as follows: the horizontal counter begins at a value of zero, with the HSYNC* and SERRATION* waveforms active (i.e. low). When the counter reaches the HSNP value, HSYNC* is deasserted on the next serial clock. The horizontal counter continues counting up until the programmed HSERNP value is reached, at which point the SERRATION* waveform is deasserted on the next serial clock. The horizontal counter continues until the HSAP value is reached, after which the horizontal counter will be restarted at zero on the next serial clock. A diagram illustrating the relative register values related to active screen area is shown in FIG. 4, "Timing Generation-Non-Interlaced Format." Timing diagrams for the generation of composite sync are shown in FIG. 5, "Horizontal Timing and Composite Sync Generation-Non-Interlaced Format."
The generation of the horizontal blanking signal is relatively straightforward-HBLANK* is asserted on the next serial clock, after the horizontal counter reaches the value programmed in the HBAP (Horizontal Blank Assertion Point) register. HBLNK* is then deasserted on the next serial clock, after the horizontal counter reaches the value programmed in the HBNP (Horizontal Blank Negation Point) register.
The horizontal timing register values should satisfy the following relationships:
0<HSNP<HBNP<HBAP<HSAP
Vertical Timing Generation
The VSYNC* vertical timing signal is generated using the values contained in the VSNP (Vertical Sync Negation Point) and VSAP (Vertical Sync Assertion Point) registers. The VBLANK* vertical timing signal is generated using the values contained in the VBAP (Vertical Blank Assertion Point) and VBNP (Vertical Blank Negation Point) registers. In non-interlaced mode, all vertical timing register intervals are specified in units of horizontal lines (i.e. the load period HSAP). The vertical timing counter is incremented at each horizontal sync assertion time; subsequently, the only time that any vertical timing signals may transition is at HSYNC* assertion.
The vertical timing registers should be programmed to satisfy the following relationship:
0<VSNP<VBNP<VBAP<VSAP
The composite blanking signal is derived by logically OR'ing HBLANK* with VBLANK*.
Interlaced Mode
In interlaced mode, and due to the nature of the composite sync and video signals during the equalization and vertical sync intervals, timing events are based on half-line quantities.
Horizontal Timing Generation
The HSYNC* and SERRATION* waveforms are generated in the same form as for non-interlaced mode; except that the HSYNC* and SERRATION* waveforms occur twice for each scan line. The contribution of these signals to the generation of the composite sync/video waveforms for interlaced mode is explained below. The HSYNC* and SERRATION* waveforms do not depend on scan line or the state of the FIELD signal; they are generated using only the contents of the horizontal counter. However, HBLANK* generation is also a function of the current FIELD and vertical scan line counter. The relationships between the programmed register values and the waveforms are shown in FIG. 6, "Horizontal Timing Waveforms-Interlaced Format." In this figure, for an even field, the value of n would be even, and for an odd field the value of n would be odd. The truth table for generating the horizontal blanking signal is shown in Table 5.
TABLE 5______________________________________Horizontal Blank Generation-Interlaced FormatAssert HBLANK* on next Deassert HBLANK* on nextserial clock when serial clock when Horizontal and Vertical Horizontal and VerticalField Counter = Counter is Counter = Counter is______________________________________Even HBAP Odd HBNP EvenOdd HBAP Even HBNP Odd______________________________________
Vertical Timing Generation
The registers used for vertical events in interlaced mode are the VSAP (Vertical Sync Assertion Point), VSNP (Vertical Sync Negation Point), EIAP (Equalization Interval Assertion Point), EINP (Equalization Interval Negation Point), VBAP (Vertical Blank Assertion Point), and VBNP (Vertical Blank Negation Point). Some vertical timing signals depend only on the vertical counter value (VSYNC*, EQUALIZATION*); others also depend on the current field (VBLANK*, FIELD).
The vertical counter is incremented at each leading edge of the internal HSYNC* signal; hence, all vertical timing registers must be programmed using half-line quantities (e.g. VSAP for NTSC has 525 half lines. For 525 half lines, VSAP is programmed as 524). The truth table for generating the vertical blanking signal is shown in Table 6, "Vertical Blank Generation-Interlaced Mode," below.
TABLE 6______________________________________Vertical Blank Generation-Interlaced ModeAssert VBLANK* on next Deassert VBLANK* on nextHSYNC* leading edge when HSYNC* leading edge when Vertical and Vertical Vertical and VerticalField Counter ≧ Counter is Counter > Counter is______________________________________Even HBAP Odd HBNP EvenOdd HBAP Even HBNP Odd______________________________________
The vertical timing registers should satisfy the following relationship:
0<VSNP<EINP<VBNP<VBAP≦EIAP≦VSAP
Composite Sync Generation
The composition of the composite sync signal during the various frame intervals is shown in Table 7, "Composite Sync Generation-Interlaced Format," below. The relationships between the HSYNC* and SERRATION* signals relative to the VBLANK*, VSYNC*, and EQUALIZATION* signals and vertical counter values are illustrated in FIG. 7, "NTSC Video
TABLE 7__________________________________________________________________________Composite Sync Generation-Interlaced Format Assert CSYNC* on next Deassert CSYNC* on next serial clock when serial clock when and andField During Interval HCounter = VCounter is HCounter = VCounter is__________________________________________________________________________ Other HSAP Even HSNP Even or OddOdd Pre-equalization or Post- HSAP Even or Odd EQNP Even or Odd equalization Vertical Sync HSAP Even or Odd HSERNP Even or Odd Other HSAP Odd HSNP Even or OddEven Pre-equalization or Post- HSAP Even or Odd EQNP Even or Odd equalization Vertical Sync HSAP Even or Odd HSERNP Even or Odd__________________________________________________________________________
When HSYNC* and/or VSYNC* is disabled with the controls shown in Table 2, "Timing Generator Control Register," the composite SYNC is as shown in Table 8, "Composite Sync Output when HSYNC* & VSYNC*
TABLE 8______________________________________Composite Sync Output when HSYNC* & VSYNC* Enabled/DisabledMode HSYNC* VSYNC* CSYNC output______________________________________Non-interlaced enabled enabled Normal operation enabled disabled CSYNC* looks like HSYNC* (no serrations) disabled enabled CSYNC* looks like VSYNC* (no serrations) disabled disabled CSYNC* inactiveInterlaced enabled enabled Normal operation enabled disabled Undefined disabled enabled Undefined disabled disabled CSYNC* inactive______________________________________
Output Signals
The RAMDAC provides the following timing generator outputs: SC*, SCen*, STSCAN, FIELD, and CSYNC*. The composite signal waveform is as previously described; the timing at the CSYNC* output pin is consistent with the analog DAC outputs.
FIELD Output
The FIELD signal, when in master mode, transitions with the leading edge of the internal VSYNC*; additionally, the level is used to output the current field when in interlaced mode (logical zero=even field, logical one=odd field). In non-interlaced mode, transitional edges of this signal will still occur near the leading edge of every VSYNC*, however the level of the FIELD signal has no meaning; externally it may be used to differentiate between left and right views of a stereo display
STSCAN Output
This output is an internally generated signal This signal may be used by the memory controller of the host CPU to determine the proper row transfer address timing for the frame buffer serial port. The STSCAN logic will set the STSCAN at the falling edge of SCen if the next line is visible and reset the STSCAN at the rising edge of SCen.
SCen Output
The SCen (Serial clock enable) output is used for enabling the clocking of the serial data from the frame buffer memories. The assertion of SCen is controlled by programming the timing generator registers VBNP, VBAP, HSCenAP (Horizontal Serial Clock Enable Assertion Point), and HSCenNP (Horizontal Serial Clock Enable Negation Point).
Slave Mode Operation
When the timing generator control register is programmed to slave mode, the timing generator accepts the FIELD signal as an input. In this mode, a transition occurring on this input will cause the vertical counter to be reset at the subsequent horizontal sync occurrence. If the RAMDAC is in interlaced mode, the level that the FIELD signal input transitions to will determine which field is current (i.e. a high-to-low transition causes the timing generator to start at the top of an even field on the next HSYNC* leading edge). Since the horizontal counters are not reset, eventually the clock drift will cause vertical sync for the slave to be one line longer, or the blanked front porch to be one line shorter.
FIG. 8 is a block overview diagram showing the signals input to and output from the video timing generator 50 of the present invention. The signals shown correspond to the signals with the same names described above with reference to FIG. 3, excepting that Register Address is an address placed on D 07:00! and multiplexed with data placed on D 07:00!, The video clock signal and the serial clock signal are produced by the PLL clock synthesizer and pixel clock divider components of digital-analog converters (DAC) 45a-45c and PLL clock synthesizer, pixel clock divider and video timing generator 49 shown in FIG. 3 from a crystal oscillator input in a manner well known to those skilled in the art. The serial clock signal (SC*) is generated for the external clocking of the VRAM frame buffer and for the internal clocking of the video timing generator
FIG. 8 depicts the interfaces connecting the video timing generator 50, the VRAM frame buffer 15a-15d and rendering controller 14. The purpose of this diagram is to show all of the paths taken by the FIELD signal. The connection to the rendering controller is provided to explain how the left and right eye video data are obtained from the frame buffer. In the rendering controller, the FIELD signal functions as a portion of the address which is passed to the frame buffer for copying video data from main memory into its serial shift registers. Video data are clocked out of these shift registers by the action of the serial clock, SC*, and the serial clock enable, SCen*, signals.
When stereoscopic mode is active, the frame buffer memory is organized such that a single bit of address is sufficient to differentiate between memory locations containing left eye video data and those containing right eye video data.
FIG. 9 is a detailed block diagram showing the various functional blocks used to implement a video timing generator according to the present invention. The functional blocks are registers 51, horizontal and vertical counters 53, field generator 55, equality comparators 57 and event registers 59. Again, the signals shown correspond to the signals with the same names described above with reference to FIG. 3. Horizontal radix and vertical radix are set to the number of pixels on each scan line and the number of scan lines respectively for the video display connected to the RAMDAC. Vertical count is the current scan line and horizontal count is the current pixel on the current scan line. Event assertion and negation points are the values stored in registers 51 as shown in Table 4 and are loaded by the host CPU. Equality comparators 57 are a set of comparators which compare the horizontal and vertical counts to their respective radix values. The horizontal and vertical counts change on video clock boundaries. The operation of equality comparators 57 produces an output which toggles a corresponding flip-flop shown in FIG. 9 as event registers 59. The outputs of the flip-flops produce the CSYNC*, STSCAN, SCen* and composite blanking signals.
Referring to FIG. 10, field generator 55 generates the FIELD signal as follows. Equality comparator 61 (M1) receives the output of the vertical counter, V COUNT and the vertical radix, V RADIX. The former changes continuously, while the latter is a static value contained in a programmable register. The output of M1 is asserted when the two input values are equal in magnitude. V COUNT represents the number of the video line currently being processed. Consequently, the output of M1 will remain asserted for a period of time equal to that of one video scan line. It is necessary to process the output of M1 so that the resulting signal is referenced to the leading edge of M1 output assertion and is one video clock period in duration and is insensitive to the negation of the M1 output. If this is not done, then flip-flop 63 (M5) will toggle as long as its clock enable input is asserted. The circuit comprised of flip-flop 65 (M2), flip-flop 67 (M3) and AND gate 69 (M4) operate as an edge discriminator which performs the task.
The output of the edge discriminator (M4) is the clock enable input of flip-flop M5, whose output will toggle while clock enable is asserted. Because the clock enable signal is made to be one clock period in duration, the output of flip-flop M5 will change state once per video field. Tri-state driver 71 (M6), receives the output of flip-flop M5, and, if the master mode has been selected, drives the FIELD signal.
Note that the output of the edge discriminator M4 is also connected to the A input of the multiplexor 73 (M11). When the master mode is selected, the multiplexor passes the output of the edge discriminator. The resulting signal is called FIELD RESET. It is used to reset the horizontal and vertical counters of the video timing generator.
If the circuit is operated in the slave mode, tri-state driver M6 enters the high impedance state and no longer drives the signal FIELD. Instead, the FIELD signal becomes an input to the field generator 55, The selection of the slave mode also causes the B input of multiplexor M11 to be selected (in the master mode, the action of flip-flops M7, M8, M9 and gate M10 is of no importance).
The (now) externally supplied FIELD signal is referenced to a clock (in another system) which operates at the same nominal frequency as the local clock. However, the phase relationships of the local clock to the external clock and the signals derived from these clocks can only be defined as variable. Therefore, it is necessary to guard against metastability. Flip-flops 75 and 77 (M7 and M8) are hardened against metastability and are used to synchronize the externally supplied FIELD signal to the local clock (such hardened flip-flops are commonly found in ASIC cell libraries).
The FIELD signal is a square wave whose points of transition are congruent to vertical synch. Each transition point, therefore, corresponds to the point in time where V COUNT is equal to V RADIX. In order to reset the vertical and horizontal counters correctly, it is necessary to detect these transitions Flip-flop 79 (M9) and XOR gate 81 (M10) form a transition detector which is insensitive to the direction of the transition producing an output pulse with a duration of one video clock period. Since slave mode has been selected, multiplexor M11 passes the output of gate M10 and drives the FIELD RESET signal.
Further details concerning the operation of equality comparators 57 are described with reference to FIG. 11. FIG. 11 represents the comparisons performed to generate a particular timing signal of the video timing generator. Counter 53a is loaded with the radix of the timing signal. Counter 53a increments each video clock and the count is provided to comparators 57a and 57b. The comparators 57a and 57b compare the current count with the assertion point value and negation point value previously loaded in registers 51a and 51b respectively. The comparators toggle event register 59a, which is a JK flip-flop, based on the comparison results, and the output of the flip-flop provides the particular timing signal.
FIG. 12 shows the timing of the signals produced within field generator 55 for master mode timing. FIG. 13 shows the timing of the signals produced within field generator 55 for slave mode timing. | A method and apparatus for synchronizing the vertical blanking of multiple frame buffers which may exist on the same computer or separate computers for certain applications including stereo display, virtual reality and video recording, which require such synchronization. To obtain the required synchronization one frame buffer is designation as the master. It provides a signal called FIELD that changes state (0 to 1 or 1 to 0) at the start of every vertical sync event on the master frame buffer. All other frame buffers are set to be slaves. Their timing generators sample the master's FIELD signal. When they detect the master's FIELD signal changing state, they set their own internal timing to match to thereby achieve frame synchronization. | 7 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to an insulating film for use in motor of refrigeration compressor. More particularly, the present invention relates to an insulating film for use in motor of refrigeration compressor, which has excellent resistances to the substitute flon and refrigerating machine oil (e.g. synthetic lubricating oil) used in particular combination in the refrigeration compressor and moreover imparts deterioration resistance to the refrigerating machine oil.
(2) Description of the Prior Art
Flon gases, which have been used as a refrigerant for air conditioner or refrigerating machine, are believed to be a cause for ozone layer destruction and global warming, and the use of particular flons having a high ozone depletion potential, such as R11 (CCl 3 F), R12 (CCl 2 F 2 ) and the like must be totally banned by 2,000 according to the decision made at the Copenhagen Agreement in November 1992, amended in the Montreal Protocol. In this connection, change of flon gases to substitute flons such as hydrofluorocarbons (HFC), hydrochlorofluoro-carbons (HCFC) and the like is taking place. Of the substitute flons, R134a (CH 2 F--CF 3 ) is drawing high attention and is coming to be used practically.
R134a, however, is not compatible with mineral oils which have been used as a lubricating oil for refrigeration compressor. Hence, synthetic oils of polyoxyalkylene glycol type, ester-modified polyoxyalkylene glycol type, ester type or the like are coming to be used as a new lubricating oil for refrigeration compressor.
The motor of air conditioner or refrigerating machine is used as a motor of compressor for refrigerant and is constantly placed in an atmosphere where the above-mentioned refrigerant and lubricating oil coexist. Therefore, when the compressor is in operation, the coil of the motor comes in contact with a gaseous refrigerant of high temperature and high pressure, a lubricating oil containing a large amount of the refrigerant dissolved therein, etc.; when the compressor is in stop, a liquid-state refrigerant is accumulated inside the compressor. Thus, the insulating film used for insulation of the above motor is exposed to such conditions over a long period of time and yet is required to have a semi-permanent life.
As such an insulating film, there has been widely used a polyethylene terephthalate (hereinafter abbreviated to PET) film for its balanced properties in heat resistance, solvent resistance, electrical insulation, mechanical strengths, etc. The PET film, however, is liable to hydrolysis by the water present in refrigerating machine oil of polyalkylene glycol type, ester-modified polyalkylene glycol type, ester type or the like, and has inevitably shown significant reduction in mechanical strengths and electrical insulation.
Also in the PET film, the low-molecular materials, etc. contained therein are extracted by the above-mentioned synthetic lubricating oil having a higher solvency for organic substances than mineral oils have, resulting in sludge formation and film embrittlement; thus, there has been a fear of reduction in compressor life.
Recently, as the output of compressor has become larger, the heat resistance and pressure resistance requirements for the insulating film of compressor motor have also become larger. In this connection, study on use of polyimide film, polyamideimide film or the like is under way. These films, however, are not satisfactory because they cause hydrolysis by the water contained in the refrigerating machine oil used in combination with a substitute flon and thereby generate organic acids, which may invite deterioration of the refrigerating machine oil and resultant reduction in refrigerating capacity.
OBJECT AND SUMMARY OF THE INVENTION
In view of the above situation, the object of the present invention is to provide an insulating film for use in motor of refrigeration compressor, which has excellent hydrolysis resistance, generates no sludge, resultantly prevents reduction in insulation, and further has a deterioration resistance to refrigerating machine oil.
In order to solve the above-mentioned problems of the prior art, the present inventors made a study. As a result, the present inventors found out that the above object can be achieved by using, as an insulating film, a carbodiimide film obtained by adding, to a base film, a particular compound having at least one carbodiimide group in the molecule, or by coating the particular compound on the base film, or by using essentially the particular compound. The finding has led to the completion of the present invention.
According to the present invention, there is provided an insulating film for use in the motor of a refrigeration compressor using a substitute flon and a refrigerating machine oil in particular combination, which film is obtained by adding, to a base film, a compound having at least one carbodiimide group, represented by the following formula (1) ##STR5## (wherein R 1 , is an isocyanate residue, and n 1 is an integer of 1 or more), or the formula (2) ##STR6## (wherein R 2 is an isocyanate residue; R 3 and R 4 are each a terminal group; and n 2 is an integer of 1 or more), or the formula (3) ##STR7## (wherein R 5 and R 6 are each an isocyanate residue; Y is a residue of a compound having a functional group reactive with isocyanate; and n 3 and m are each an integer of 1 or more), or the formula (4) ##STR8## (wherein R 7 is an isocyanate residue; R 8 and R 9 are each a terminal group; and n 4 is an integer of 1 or more).
According to the present invention, there is also provided an insulating film for use in the motor of a refrigeration compressor using a substitute flon and a refrigerating machine oil in particular combination, which film is obtained by coating, on the surface of a base film, a compound having at least one carbodiimide group, represented by the above formula (1) or the formula (2) or the formula (3) or the formula (4).
According to the present invention, there is further provided an insulating film for use in the motor of a refrigeration compressor using a substitute flon and a refrigerating machine oil in particular combination, which film is made essentially of a compound having at least one carbodiimide group, represented by the above formula (1) or the formula (2) or the formula (3) or the formula (4).
DETAILED DESCRIPTION OF THE INVENTION
The present invention is hereinafter described in detail.
In the present invention, "insulating film for use in motor of refrigeration compressor" refers to, for example, a film used in a motor of refrigeration compressor which has a first winding and a second winding, in the form of layer insulation, slot insulation, slot wedge or the like to separate the windings from each other for prevention of their contact.
In the present invention, the insulting film for use in motor of refrigeration compressor is obtained by adding to a base film, or coating on the surface of a base film, a compound having at least one carbodiimide group, or, is made essentially of a compound having at least one carbodiimide group (the compound is hereinafter abbreviated to "carbodiimide compound" in some cases).
The compound having at least one carbodiimide group, used in the present invention includes group (I) compounds represented by the following formula (1): ##STR9## (wherein R 1 is an isocyanate residue, and n 1 is an integer of 1 or more); group (II) compounds represented by the following formula (2): ##STR10## (wherein R 2 is an isocyanate residue; R 3 and R 4 are each a terminal group; and n 2 is an integer of 1 or more); group (III) compounds represented by the following formula (3): ##STR11## (wherein R 5 and R 6 are each an isocyanate residue; Y is a residue of a compound having a functional group reactive with isocyanate; and n 3 and m are each an integer of 1 or more); and group (IV) compounds represented by the following formula (4): ##STR12## (wherein R 7 is an isocyanate residue; R 8 and R 9 are each a terminal group; and n4 is an integer of 1 or more).
In the formula (1) of the group (I) compounds, R 1 can be exemplified by the following groups: ##STR13##
In the formula (1) of the group (I) compounds, n 1 is an integer of 1 or more. The formula (1) indicates a state in which polymerization has proceeded sufficiently. When polymerization has not proceeded sufficiently, the group (I) compounds are represented more appropriately by the following formula: ##STR14## (wherein R 1 s may be the same or different). This applies also to the formula (3) of the group (III) compounds described later.
In the formula (2) of the group (II) compounds, R 3 and R 4 are each a terminal group by a residue of a compound having a functional group such as --NH 2 , --NHX, --COOH, --SH, --OH or --NCO, or the following structures: ##STR15##
In the formula (2) of the group (II) compounds, n 2 is an integer of 1 or more; and R 2 can be exemplified by the same groups as mentioned with respect to R 1 in the formula (1) of the group (I) compounds.
In the formula (3) of the group (III) compounds, Y is a residue of a compound having a functional group reactive with isocyanate, and can be exemplified by the following structures: ##STR16## wherein Z is an alkylene group, a bivalent cycloalkyl group, a bivalent cycloalkyl group having a substituent(s) , a bivalent aryl group, a bivalent aryl group having a substituent (s), one of the following groups: ##STR17## or a group wherein one of the above structures has a substituent(s) such as lower alkyl group, lower alkoxy group or the like!.
Therefore, the group (III) compounds represented by the formula (3) are carbodiimide copolymers. In the formula (3) of the group (III) compounds, n 3 and m are each an integer of 1 or more; R 5 can be the same group as mentioned with respect to R 1 in the formula (1) of the group (I) compounds; and R6 can be the same group as mentioned with respect to R 1 in the formula (1) of the group (I) compounds, or the same group as mentioned with respect to bivalent Z in the formula (3) of the group (III) compounds.
In the formula (4) of the group (IV) compounds, R 8 nd R 9 can each be exemplified by isocyanate residues such as shown below: ##STR18## Incidentally, R 8 and R 9 may be the same or different.
A group (IV) compound of the formula (4) wherein n 4 is 0, can be obtained by reacting two monoisocyanates each having the above-mentioned isocyanate residue.
The present insulating film for use in motor of refrigeration compressor can be obtained by, as mentioned above, adding the above-mentioned carbodiimide compound to a base film heretofore used as an insulating film for motor of refrigeration compressor, or by coating the carbodiimide compound on the base film, or by making an insulating film essentially with the carbodiimide compound.
When the carbodiimide compound is added to a base film heretofore used as an insulating film for motor of refrigeration compressor, the amount of the carbodiimide compound added is, for example, 0.05-50 parts by weight, preferably 0.1-30 parts by weight per 100 parts by weight of the base film. When the amount is less than the above lower limit, no intended effect is obtained. When the amount is more than the above upper limit, increase in effect is not so high as expected and, in some cases, gives a film of impaired properties.
The base film can be a known film such as polyester film, polyimide film, polyamideimide film, polyetherimide film, aromatic polyamide film, polyhydantoin film, polyparabanic acid film, polyethersulfone film or the like.
The method of adding the carbodiimide compound to the base film may be a known method. When the base film is, for example, a thermoplastic film, the method includes, for example, (1) a method of adding a carbodiimide compound in production of resin pellets which is a raw material of base film, and (2) a method of adding a carbodiimide compound to a film produced by casting or to a material to be casted.
When the carbodiimide compound is coated on the base film, the compound is preferably a film-formable compound selected from the group (I) compounds, the group (II) compounds, the group (III) compounds and the group (IV) compounds. Preferred are group (I) compounds wherein n 1 ≧20; group (II) compounds wherein n 2 ≧30; group (III) compounds wherein n 3 ≧20 and m≧1, or n 3 ≧1 and m≧15; and group (IV) compounds wherein n 4 ≧20.
The method used for coating the carbodiimide compound on the base film can be a known method. There can be used, for example, a method which comprises dissolving a carbodiimide compound having at least one carbodiimide group, in a solvent to prepare a solution, immersing a base insulating film in the solution or coating the solution on the film, subjecting the resulting material to solvent removal, and heat-treating the solvent-removed material. The thickness of the carbodiimide compound layer formed on the base film is 1-50 μm, preferably 5-20 μm. When the thickness is less than 1 μm, no intended effect is obtained. When the thickness is more than 50 μm, increase in effect is not so high as expected and, in some cases, gives a film of impaired properties.
When the thickness can be more than 50 μm, the present insulating film can be made with a group (I), or group (II) or group (III) compound alone.
The method used for making an insulating film essentially with the carbodiimide compound can also be a known method. There can be used, for example, a method which comprises casting a solution containing the carbodiimide compound, and forming the carbodiimide compound powder under pressure and heating.
The present invention is hereinafter described by way of Examples and Test Example. However, the present invention is not restricted thereto.
In the Examples, the following compounds 1-5 each having a carbodiimide group(s) were used. Incidentally, the expression n=∞ used in the compounds 1, 4 and 5 indicates that the terminal functional groups are not detected by FT-IR analysis and are substantially absent and the compounds are high-molecular compounds. ##STR19##
EXAMPLE 1
100 parts by weight of commercial polyethylene terephthalate pellets for film making and 8 parts by weight of the compound 2 were dry-blended. The blend was placed in a hopper and fed into an extruder to knead the blend at 240-270° C. The kneaded material was extruded from the extruder T die with stretching being applied, to prepare an intended film (1) having a thickness of 100 μm.
EXAMPLE 2
54.0 g of 80-TDI (a 80/20 mixture of 2,4-tolylene diisocyanate and 2,6-tolylene diisocyanate) was reacted at 120° C. for 4 hours in the presence of 0.11 g of a carbodiimidization catalyst (1-phenyl-3-methyl-2-phospholene-1-oxide) in 500 ml of tetrachloroethylene to obtain a solution of a polycarbodiimide having a structure of compound 1, which showed no absorption of isocyanate group by infrared absorption analysis (hereinafter abbreviated to IR). The solution was subjected to film formation by casting, to obtain a polycarbodiimide film (2) having a thickness of 80 μm.
EXAMPLE 3
A commercial polyethylene terephthalate film having a thickness of 50 μm was immersed in the polycarbodiimide solution of Example 2 to prepare an intended film (3) having a thickness of 80 μm, which is a polyethylene terephthalate film having, on each side, a compound 1 layer having a thickness of about 15 μm.
EXAMPLE 4
A commercial polyamideimide powder was dissolved in N-methyl-2-pyrrolidone to obtain a solution containing 20% by weight of the polyamideimide powder. To 100 parts by weight of this polyamideimide solution was added 7 parts by weight of an N-methyl-2-pyrrolidone solution containing 20% by weight of the compound 4, to prepare a varnish. The varnish was subjected to film formation by casting, followed by solvent removal and annealing, to prepare an intended film (4) having a thickness of 80 μm, having amide group, imide group and carbodiimide group.
EXAMPLE 5
17.4 g of 80-TDI was reacted with 16.1 g of benzophenonetetracarboxylic acid anhydride in 300 ml of nitrobenzene at 150° C. for 4 hours. Thereto was added 200 ml of N-methyl-2-pyrrolidone and 0.02 g of a carbodiimidization catalyst, and a reaction was conducted at 150° C. for 20 hours to obtain a solution of a polycarbodiimide having a structure of compound 5, which showed no absorption of isocyanate group by IR. The solution was subjected to film formation by casting, followed by solvent removal, to obtain an intended polycarbodiimide film (5) having a thickness of 80 μm.
EXAMPLE 6
57.8 g of p-MDI (pure diphenylmethane diisocyanate) was reacted with 1.1 g of phenyl isocyanate in the presence of 0.12 g of a carbodiimidization catalyst (1-phenyl-3-methyl-2-phospholene-1-oxide) in 500 ml of tetrahydrofuran at 65° C. for 20 hours, to obtain a solution of a polycarbodiimide having a structure of compound 3, which showed no absorption of isocyanate group by IR. The solution was subjected to film formation by casting, to obtain a polycarbodiimide film (6) having a thickness of 80 μm.
EXAMPLE 7
The polycarbodiimide film having a structure of compound 1, obtained in Example 2 was treated at 200° C. for 5 minutes to obtain an intended polycarbodiimide film (7) wherein part of the carbodiimide groups was dimerized to form a crosslinked structure.
Test Example
50 ml of a commercial ester type oil was placed in a 100-ml autoclave. In the autoclave were also placed three rectangular (3 cm×6 cm) test pieces prepared by cutting one of the films prepared in Examples 1-7, so that the test pieces were immersed in the oil. Then, the autoclave was tightly sealed, heated at 175° C. for 10 days, and then opened. Thereafter, (1) the total oxidation numbers of the oil before and after the heating and (2) the tensile strengths of the film before and after the heating were measured. The results are shown in Table 1.
COMPARATIVE EXAMPLE 1
50 ml of a commercial ester type oil and a commercial polyethylene terephthalate film having a thickness of 80 μm were heated in an autoclave in the same manner as in Test Example. Then, (1) the total oxidation numbers of the oil before and after the heating and (2) the tensile strengths of the film before and after the heating were measured in the same manner as in Test Example. The results are shown in Table 1.
COMPARATIVE EXAMPLE 2
50 ml of a commercial ester type oil alone was heated in an autoclave in the same manner as in Test Example. Then, the total oxidation numbers of the oil before and after the heating were measured. The results are shown in Table 1.
TABLE 1______________________________________ Total Oxidation Numbers Tensile Strength of Film of Oil (mg KOH/g) (kfg/mm.sup.2) Before After Before After Heating Heating Heating Heating______________________________________Film 1 0.02 0.25 15.4 9.8Film 2 0.02 0.18 17.9 14.5Film 3 0.02 0.15 14.8 11.0Film 4 0.02 0.21 13.4 11.7Film 5 0.02 0.20 14.1 12.6Film 6 0.02 0.17 13.3 10.2Film 7 0.02 0.19 15.9 13.6Comparative 0.02 0.35 16.2 Unable toExample 1 Measure*Comparative 0.02 0.33 -- --Example 2______________________________________ *Test pieces deteriorated and became brittle, and could not be fitted to tensile strength tester.
The present insulating film for use in motor of refrigeration compressor, comprising a polycarbodiimide, as compared with conventional insulating films, has higher resistances to refrigerating machine oil and refrigerant and can prevent deterioration of insulation.
Further, with the present insulating film for use in motor of refrigeration compressor, the carbodiimide groups possessed by the polycarbodiimide of the film can capture (a) the acid components (e.g. carboxylic acids and phosphoric acid) generated by the decomposition of refrigerating machine oil, refrigerant and additives and (b) water which causes the hydrolysis of ester bond of refrigerating machine oil, and thereby can prevent oxidation number increase in refrigeration compressor system. | The present invention provides an insulating film for use in the motor of a refrigeration compressor using a substitute flon and a refrigerating machine oil in particular combination, which film is obtained by adding to a base film, or coating on the surface of a base film, a compound having at least one carbodiimide group, or, which film is made essentially of a compound having at least one carbodiimide group, represented by the following formula (1): ##STR1## or the following formula (2): ##STR2## or the following formula (3): ##STR3## or the following formula (4): ##STR4## This insulating film can eliminate the problems of the prior art, has excellent resistance to hydrolysis and forms no sludge, resultantly can prevent reduction in insulating property, and further has deterioration resistance to refrigerating machine oil. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to a mass transport device, particularly a rotation pack bed, and a method for removing volatile components from a high viscosity liquid.
BACKGROUND OF THE INVENTION
[0002] Triarylphosphite P(OAr) 3 is an additive commonly used in the plastic processing as an antioxidant, wherein Ar represents an aryl group. A conventional method for preparing this antioxidant comprises a chemical reaction step and a step of removing by-products. The two steps are separately described herein below:
[0003] Chemical Reaction Step:
[0004] To a batch agitation tank an ArOH liquid is added, and PCl 3 is slowly added into the tank while stirring. The chemical reactions carried out in the tank are shown in the following:
ArOH+PCl 3 ⇄ArOPCl 2 +HCl (1)
ArOH+ArOPCl 2 ⇄(ArO) 2 PCl+HCl (2)
ArOH+(ArO) 2 PCl⇄(ArO) 3 P+HCl (3)
[0005] The by-product HCl in the formulas (1), (2) and (3) is a volatile gas. The HCl gas makes a large amount of foams in the viscous reaction liquid, creating an overflow from the tank, so that the batch agitation tank is not allowed to accept feeds continuously and rapidly. As a result, the retention time of a batch of 4 tons requires more than 10-hours processing.
[0006] Step of Removing By-Product:
[0007] The by-product HCl generated during the chemical reaction step must be removed from the reaction system, thereby breaking the equilibrium of the chemical reaction and increasing the yield of the anti-oxidant P(OAr) 3 . A conventional method of removing HCl comprises blowing an inert gas at normal pressure into the product mixture to an acid value of 3 mgKOH/g, then forming a vacuum and blowing an inert gas to the mixture again to a market acceptable acid value of 0.1 mgKOH/g. It takes more than 12 hours for removing HCl from the product mixture to the acid value of 0.1 mg KOH/g.
[0008] Herzog and Hoppe (U.S. Pat. No. 3,823,207) in 1974 has disclosed a method for preparing a triarylphosphite anti-oxidant, wherein a conventional batch process using an agitation tank is changed into a continuous process of an overflow-type reaction tank formed by a shallow dish added with a partition plate. The ratio of area to volume of the reaction region formed by the overflow partition plate is larger than that of a conventional agitation tank. A larger area to volume ratio can be formed when a reaction fluid passes through an overflow partition plate. This is beneficial to the contact of reactants and the removal of HCl gas. Furthermore, the reaction liquid is added with a high-boiling solvent, which is inert to PCl 3 , in order to reduce the viscosity of the reaction liquid. The abovementioned improvement measures are used to increase the feeding rate of the raw materials. Even though the reaction retention time is shorter than that of the conventional batch process, the added solvent needs to be separated by a distillation process, thereby greatly increasing the energy consumption.
SUMMARY OF THE INVENTION
[0009] A primary objective of the present invention is to provide a method for removing volatile components from a high viscosity liquid by using a rotation pack bed.
[0010] Another objective of the present invention is to provide a method for preparing a product by using a rotation pack bed to conduct a reaction of a high viscous liquid and another fluid, while removing a volatile by-product at the same time.
[0011] In the present invention, a high viscosity liquid is fed into a rotation pack bed at a position with a distance far enough from a rotation axis, creating a centrifugal force exerted on the high viscosity liquid, which overwhelms a drag thereof, so that it can flow radially through the rotation pack bed.
BRIEF DESCRIPTION OF THE DRAWING
[0012] [0012]FIG. 1 is a schematic cross-sectional view of a multi-liquid-type rotation pack bed reaction system according to the present invention.
LEGENDS
[0013] [0013] 1 . driving motor
[0014] [0014] 2 . transmission shaft
[0015] [0015] 3 . pack bed
[0016] [0016] 4 . rotation drum
[0017] [0017] 5 . first liquid inlet
[0018] [0018] 6 . second liquid inlet
[0019] [0019] 7 . distribution dish
[0020] [0020] 8 . gas outlet
[0021] [0021] 9 . liquid outlet
[0022] [0022] 10 . gas inlet
[0023] [0023] 11 . sealing device
[0024] [0024] 12 . mechanical shaft seal
[0025] [0025] 13 . internal circulation pump
[0026] [0026] 14 . internal circulation pipeline
[0027] [0027] 15 . recycling ratio control valve
DETAILED DESCRIPTION OF THE INVENTION
[0028] An apparatus for performing mass transfer by counter currently contacting two fluids with different specific gravities was known by the persons skilled in the art, e.g. U.S. Pat. Nos. 4,283,255; 4,382,045; 4,382,900; and 4,400,275. China Patent Publication No. CN1116146A (1996) discloses a method for preparing ultra-fine particles by using said mass-transfer apparatus, wherein liquid streams are fed to an axis of a rotation pack bed through a distributor from the inner pipe and annular space of two concentric tubes, and contact and react with each other in the rotation pack bed by the centrifugal effect. U.S. Pat. No. 6,048,513 (2000) provides a process for preparing hypohalous acid by using a rotation pack bed, which comprises counter currently contacting a liquid reactant with a chlorine gas through a rotation pack bed rotating at a high speed; and separating the gas from the liquid. The process comprises adsorption, reaction and desorption. The rotation pack bed can increase the yield of the process to 90% compared to a yield of 80% of the conventional process, while using a gas flow 50% lower than that used by the conventional process. The viscosities of the liquid feeds in the abovementioned China Patent Publication No. CN1116146A and U.S. Pat. No. 6,048,513 are all very small (about 1 cp at 25° C.). Therefore, the liquid feeds still receive a sufficient rotation centrifugal field when fed at a location near the axis of the rotation pack bed, and flows radially through said pack bed.
[0029] In the abovementioned method for preparing the P(OAr) 3 antioxidant described in the Background of the Invention, the inventors of this application deem that overcoming the mass transfer limit of HCl in the viscous reaction fluid is a key factor in accelerating the production process, increasing the yield of the P(OAr) 3 antioxidant, and reducing the acid value of the P(OAr) 3 antioxidant. Therefore, the present inventors think of using a rotation pack bed to promote the reactants mixing and mass transfer rate of HCl in the viscous reaction liquid. However, if the highly viscous ArOH liquid is fed to the axis position of the rotation pack bed as in the conventional process, said highly viscous ArOH liquid will stay there due to its high viscosity and can not radially flow through the rotation pack bed. In order to solve this problem, the present inventors develop a novel rotation pack bed, wherein an inlet for said high viscosity liquid is installed at a location far enough from the axis in order to generate a sufficient centrifugal force to promote said high viscosity liquid flowing through said rotation pack bed.
[0030] The present inventors also provide a method for removing volatile components from a high viscosity liquid, e.g. removing an unreacted polyisocyanate monomer from a highly viscous polyurethane, and removing HCl from a high viscosity tris nonylphenol phosphite anti-oxidant.
[0031] A method for removing volatile components from a high viscosity liquid by using a rotation pack bed embodied according to the present invention comprising the following steps:
[0032] a) introducing a high viscosity liquid into a rotation pack bed rotating around an axis, said rotation pack bed being located in a housing and comprising a central channel region around said axis and an annular pack region surrounding said central channel region, said annular pack region being packed with a packing, and said annular pack region and said central channel region being in fluid communication only through a boundary thereof, and said annular pack region and said housing being in fluid communication only through an outer circumference of said annular pack region, wherein said high viscosity liquid is introduced to a location in said annular pack region so that said high viscosity liquid receives a sufficient centrifugal force at said location and can radially flow through said packing from said location in a direction away from said axis;
[0033] b) introducing a high pressure gas at a location near the outer circumference of said annular pack region, and/or connecting said central channel region to a suction source so that, when said highly viscous fluid radially flows through said packing, a volatile component in said high viscosity liquid together with said high pressure gas or said volatile component per se flow out of said rotation pack bed and said housing in a gas phase from said central channel region; and
[0034] c) collecting a purified liquid, which flows out from the outer circumference of said annular pack region, from a bottom of said housing.
[0035] Said high viscosity liquid in step a) of the method of the present invention preferably has a viscosity less than 3000 cps at room temperature.
[0036] Preferably, said high viscosity liquid in step a) comprises tris nonylphenol phosphite, and hydrogen chloride contained in said tris nonylphenol phosphite, wherein said volatile component is said hydrogen chloride, and said purified liquid is a tris nonylphenol phosphite having a reduced amount of hydrogen chloride.
[0037] Preferably, said high viscosity liquid in step a) comprises polyurethane and an unreacted polyisocyanate monomer contained in said polyurethane, wherein said volatile component is said polyisocyanate monomer, and said purified liquid is a polyurethane having a reduced amount of polyisocyanate monomer.
[0038] Preferably, in step b), a high pressure nitrogen gas is introduced into said housing as said high pressure gas.
[0039] Preferably, the method of the present invention further comprises recycling a portion of the purified liquid in step c) to step a) and into said annular pack region.
[0040] Preferably, in step b), a high pressure gas is introduced into said housing, which contacts and reacts with the high viscosity liquid when said high viscosity liquid is radially flowing through said packing material, wherein a product of the chemical reaction together with unreacted high pressure gas flows out said rotation pack bed and said housing in a gas phase from said central channel region, and another product of the chemical reaction is collected at the bottom of said housing together with unreacted high viscosity liquid.
[0041] Preferably, step a) further comprises introducing a liquid reactant from said central channel region to said rotation pack bed, said liquid reactant flowing through said packing in a radial direction away from said axis by a centrifugal force, and said liquid reactant and said high viscosity liquid generating a chemical reaction, wherein a product of the chemical reaction flows out of said rotation pack bed and said housing in a gas phase, and another product of the chemical reaction, unreacted high viscosity liquid and unreacted liquid reactant are collected at the bottom of said housing. More preferably, in step b), an inert gas is introduced into said housing as the high pressure gas. Said product of the chemical reaction together with said high pressure inert gas flows out of said rotation pack bed and said housing in a gas phase through said central channel region; and said another product of the chemical reaction and the unreacted high viscosity liquid and the unreacted liquid reactant are collected at the bottom of said housing. For example, said high viscosity liquid comprises nonylphenol, said liquid reactant comprises PCl 3 , said high pressure inert gas is nitrogen, one product of the chemical reaction is HCl which flows out of said rotation pack bed from said central channel region in a gas phase together with the nitrogen, and another product of the chemical reaction is tris nonylphenol phosphite which, together with unreacted nonylphenol and PCl 3 , is collected at the bottom of said housing.
[0042] As shown in FIG. 1, a multi-liquid type rotation pack bed reaction system suitable for use in the present invention comprises: a driving motor 1 , a transmission shaft 2 , a pack bed 3 containing a network packing, and a rotation drum 4 . Two liquid feeds are separately sprayed into the pack bed from the first inlet 5 and the second inlet 6 . The first liquid feed introduced into the first inlet 5 enters the distribution dish 7 , and is divided into tiny liquid drops which, together with the second liquid feed from the second inlet 6 , enter the pack bed 3 by the driving of the centrifugal force, wherein the two liquid feeds are fully mixed and undergo a reaction. A gaseous by-product resulting from the reaction is discharged from the gas outlet 8 , wherein said outlet 8 is installed with a branch pipe connected to an evacuation device (not shown in the drawing) to set up a vacuum environment for the reaction system. The liquid product is collected at the enclosure 16 of the main body, and is discharged from the liquid outlet 9 .
[0043] When the liquid feeds enters the rotation pack bed 3 from the first inlet 5 and the second inlet 6 , an inert gas (e.g. nitrogen, CO 2 , argon or other gas that does not participate the reaction) is introduced into the rotation pack bed 3 from the gas inlet 10 , which counter currently flows through the reaction mixture, and carries the gas by-product away from the reaction mixture to the gas outlet 8 .
[0044] In order to prevent the inert gas from gas inlet 10 by-passing to the gas outlet 8 , a sealing device 11 , which adopts a maze-type seal, is installed, the gap of the seal teeth is adjustable. A mechanical shaft seal 12 is installed on said transmission shaft 2 to prevent a leakage caused by the pressure difference between the internal pressure of the system and the outside pressure. In order to reduce the amounts of the unreacted reactants in the product mixture flowing out of the system, an internal circulation pump 13 , an internal circulation pipeline 14 , and recycling ratio control valves 15 are installed.
[0045] The contents, objectives and features of the present invention are further elaborated by way of the following examples which are for explaining the present invention instead of limiting the scope thereof.
EXAMPLES 1-3
[0046] Batchwise Removal of HCl from TNPP (Tris Nonylphenol Phosphite)
[0047] The specifications of the pack bed used in these examples were: inside diameter 76 mm, outside diameter 160 mm, and thickness 33 mm. The rotation speed of the pack bed was fixed at 1300 rpm, and nitrogen was used as a carrying agent. The inlet position of TNPP was at a location 35 mm from the axis of the pack bed. 5 kg of TNPP (having an acid value of 0.18 mgKOH/g, and a viscosity of 1000 cps) was taken. The temperature of TNPP feed and the gas/liquid ratio of nitrogen to TNPP were altered as shown in Table 1. The results were also shown in Table 1. The test results indicated that the acid value of TNPP, after 15 minutes of processing (one cycle) by the rotation pack bed, was reduced to 0.06˜0.08 mgKOH/g. After a consecutive treatment to 45 minutes (three cycles in total), the acid value of TNPP dropped to 0.04˜0.06 mgKOH/g.
TABLE 1 Example 1 2 3 Acid value of feed mg KOH/g 0.18 0.18 0.18 Acid value of discharge mg KOH/g 0.08 0.06 0.07 after 15 min. Acid value of discharge mg KOH/g 0.06 0.05 0.04 after 45 min. Temperature of feed ° C. 130 170 150 Flow rate of inlet liquid mL/min 200 200 200 Flow rate of inlet gas L/min 15 15 20 Gas/liquid ratio — 75 75 100 Rotation speed rpm 1300 1300 1300
EXAMPLE 4
[0048] Continuous Removal of HCl from TNPP
[0049] The specifications of the pack bed used in this example were: inside diameter 120 mm, outside diameter 600 mm, and thickness 100 mm. The rotation speed of the pack bed was fixed at 1200 rpm. The inlet of the TNPP feed was at a location 50 mm from the axis of the pack bed. The nitrogen temperature was 88° C., and the flow rate of nitrogen was 1250 l/min. The viscosity of TNPP was 1000 cps, the temperature of TNPP was 114° C., and the flow rate of TNPP was 25 l/min. Prior to the processing by the pack bed, the acid value of TNPP was 0.3 mgKOH/g; and the acid value decreased to 0.16 mgKOH/g after being processed. | A high viscosity liquid is fed into a rotation pack bed at a position with a distance far enough from a rotation axis, creating a centrifugal force exerted on the high viscosity liquid overwhelming a drag thereof, so that it can flow radially through the rotation pack bed. A high pressure gas is introduced into the rotation pack bed peripherally and/or a suction force source is connected to a position near the rotation axis, so that a volatile component contained in the high viscosity fluid is entrained in the gas counter currently flowing through the rotation pack bed and withdrawn from the position near the rotation axis, or the volatile component exits from the position near the rotation axis in gas phase, and thus the volatile component is removed from the high viscosity liquid. A second fluid can also be fed into the rotation pack bed to react with the high viscosity liquid, so that a reaction product is formed, and a volatile side product is removed at the same time. | 2 |
[0001] The present application is a continuation application of Ser. No. 13/178,906, filed Jul. 8, 2011, which is a continuation application of Ser. No. 11/828,729, filed Jul. 26, 2007; which is a continuation of application Ser. No. 10/614,134, filed Jul. 8, 2003, now U.S. Pat. No. 7,881,311; which is a continuation of application Ser. No. 09/392,623, filed Sep. 9, 1999, now U.S. Pat. No. 6,633,571, the contents of which are incorporated herein by reference. This application claims priority to JP 11-147663, filed May 27, 1999.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a method of composing a VPN (Virtual Private Network) on the Internet and an interwork router used to connect Internet service providers to each other.
[0003] Various applications such as E-mail and WWW (World Wide Web) programs can be used on any Internet Protocol (IP) networks. In addition, such IP networks can be composed at lower costs than the conventional switching networks that use are associated with telephones. This is why the Internet has rapidly come into wide use in recent years. Under such circumstances, intracompany networks (intranets) composed on the IP level are now indispensable for facilitating the activities of those companies.
[0004] Companies are often distributed unevenly in local areas. In such a situation, therefore, there will appear a demand that the intranets in those local areas should be connected into one network as a logical consequence. In such a case, there are the following two methods possible for connecting those intranets to each other in local areas.
[0005] Firstly, private lines are used for connecting those intranets in local areas. In this case, each of those intranets can be isolated from external networks for ensuring security.
[0006] Secondly, the IPsec (IP security protocol) technique is used to provide each terminal with a function for identifying packets of its own company's network, so that those packets are transferred on the Internet as IP packets using global addresses. This identifying function, when combined with an encoding technique, can make up a Virtual Private Network (VPN) so as to be protected from the attacks of malicious users.
[0007] If such private lines are used; however, some problems arise; for example, the network cost is increased, and furthermore, the VPN realized by the IPsec method cannot be protected from the attacks and invasions of malicious users who can crack the codes. In addition, the encoding processing becomes a bottleneck of increasing the speeds for fast networks and terminal costs are increased.
[0008] Along with the rapid spread of the Internet, as well as the cost reduction of using the Internet, there have appeared strong demands for forming virtual private networks on the Internet using the functions of lower layers than the IP layer provided by networks, while suppressing the cost and isolating each of those virtual private networks from external networks so as to assure the security and quality thereof.
[0009] In order to meet such demands, the following VPN is proposed. A packet is encapsulated at the inlet of the object network of an Internet Service Provider (ISP) that provides the VPN. On the ISP network, each packet is transferred according to the capsule header, then the capsule header is removed at the outlet of the network. According to this VPN composing method, since a packet is encapsulated peculiarly to the VPN, the VPN is isolated from external networks, thereby assuring the security of the VPN. More concretely, for such an encapsulation protocol various methods are available, such as IP encapsulation, MPOA (Multi-Protocol over ATM), MPLS (Multiprotocol Label Switching), etc. Since February of 1999, those methods have been under examination in such standardization groups as ITU-T SG13 (International Telecommunications Union-Telecommunications Standardization Section, Study Group 13), IETF (Internet Engineering Task Force), etc. In addition, ITU-T SG13 is also examining the Core Protocol of the Global Multi-media Network Connection Less (GMN-CL) for transferring packets encapsulated according to E.164 addresses in the object network.
[0010] “Access Network Systems and Edge Nodes Systems for the Next-Generation Computer Network”, pp. 425-434, NTT R&D vol. 47 No. 4, 1998 (issued on Apr. 10, 1998) has also proposed a method for composing an edge node in an accessing system used to interwork between each of a plurality of user networks and the core network in the GMN-CL.
SUMMARY OF THE INVENTION
[0011] In recent years, the areas of activities in companies have expanded more and more widely. For example, many Japanese companies have offices at overseas, including the United States of America and European countries. Under such circumstances, it would be natural for those companies to consider it important to connect the intranets composed in their offices to each other via a VPN.
[0012] On the other hand, since each ISP generally provides the services only in a specific area, the VPN must be composed over a plurality of ISPs in order to connect the networks (intranets) in those areas through the VPN.
[0013] And, if a plurality of ISPs are connected to each other in such a way, an interwork gateway (interwork router) needs to be formed for such connection. In this interwork router, the interwork is realized so as to transfer each of the packets from one of the ISP networks to the other according to the IP header. In addition, a system referred to as an IX (Internet Exchange) is used for connecting both networks to each other so as to realize the interwork among a plurality of networks as described in “Commercial IX”, pp. 146-155, Nikkei Communications Dec. 15, 1997. And, this IX may also be used to transfer IP packets among those networks. Such an IX includes some methods that use a “layer 3 forwarding” function for identifying and transferring each of the IP packets, as well as a “layer 2 forwarding” function for transferring each of the IP packets by identifying the header in the lower layer in the ATM (Asynchronous Transfer Mode) communication system, etc.
[0014] The present inventors have examined the problems which arise when a VPN is composed over a plurality of ISP networks. At first, packets are encapsulated in order to compose a VPN for the network of each Internet Service Provider. Generally, the encapsulation protocol of each network differs from other networks. In this case, the IP header information of each IP packet is retrieved by the interwork router, thereby determining the route to the destination. In this case, the retrieving must also include a check to determine whether or not the packet is to be transferred to another network. The IP header information is common for both of the networks.
[0015] However, the interwork router terminates the protocol of each layer lower than the IP layer at the interface. Therefore, the capsule header given in the previous network so as to compose the VPN is removed in the process of retrieving the IP address, so that information as to the next leg of the route can be determined. After that, a new capsule header must be generated and added to the packet so as to compose the VPN in the next network. Consequently, packets in the VPN are mixed with packets in other networks in the interwork router. And, this might cause a problem that malicious users are able to change the headers to those packets and invade the VPN through the interwork router.
[0016] Some companies do not use global addresses, but use private addresses for composing their VPNs. In such a case, once the interwork router removes the capsule header of a packet, the receiving ISP cannot distinguish the packet from others if the packet has the same address as those of other packets. This is because each of a plurality of VPNs use internal addresses uniquely. Consequently, the receiving ISP receiving cannot determine the destination of the packet. If a VPN is composed over a plurality of ISPs on the Internet, therefore, the problem as described above be solved by all means.
[0017] In addition, the types of services are not the same among ISPs. As for the communication quality, for example, assume that one ISP uses an ATM VC (Virtual Channel) for forming a communication path, thereby assuring the quality of each VPN and the other ISP uses Diffserv (Differentiated Services) to assure the quality of the communication. If the VPNs composed for both networks are to be connected to each other in such a case, it will be difficult to provide the communication quality on an end-to-end level.
[0018] As described above, it is difficult to compose a VPN over a plurality of ISPs on the Internet for practical use.
[0019] Under such circumstances, therefore, it is an object of the present invention to solve the above problems and provide a method of composing a VPN over a plurality of ISPs and provide an interwork router for connecting those ISPs to each other in such a VPN.
[0020] In order to solve the above problems, the interwork router of the present invention is provided with functions for determining the route to output packets and for generating a capsule header for each of those packets to be used in the next ISP network (in output side) from the information set both in the capsule header, which is a VPN identifier, and in the IP header of the packet. Hereunder, a more detailed description will be made of an example of how to connect a plurality of ISPs to each other. Each of those ISPs is used to operate an MPLS network that uses an ATM as a lower layer. More concretely, header information is added to each packet to be transferred to the next network. Such header information is generated when header information such as VPI, VCI, etc. (capsule headers) of the ATM are used to identify the VPS, as well as to determine the next route and identify the VPN in the next network, which header information is generated with necessary data retrieved according to an IP address as a key. And, the header information is generated and transferred together with the packet to the next network.
[0021] A VPN interwork can thus be realized, thereby enabling the VPN to be composed on the Internet in areas covering a plurality of ISPs.
[0022] The value of the field that indicates the QoS in the capsule header on the input side is mapped on the value of the field that indicates the QoS in the capsule header for the output side. Consequently, quality information of both networks composing a VPN can be transferred as is.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a schematic diagram showing an example of the operation of an interwork router according to the present invention.
[0024] FIG. 2 is a schematic diagram illustrating an example of problems solved by the present invention.
[0025] FIG. 3 is a diagram which shows the operation of the interwork router of the present invention using a protocol stack.
[0026] FIG. 4 is a flow chart indicating an ISP interworking method that uses a conventional router.
[0027] FIG. 5 is a flow chart indicating the operation of the interwork router of the present invention.
[0028] FIG. 6 is a flow chart indicating the operation of the interwork router of the present invention.
[0029] FIG. 7 is a diagram which illustrates a method for connecting an MPLS network with an IP encapsulation network using a protocol stack in an embodiment of the present invention.
[0030] FIG. 8 is a diagram which shows how an IP packet is converted to ATM cells according to RFC1483.
[0031] FIG. 9 is a diagram which shows the format of IP packets according to RFC791.
[0032] FIG. 10 is a diagram which shows the configuration of an IP tunnel packet according to RFC1853.
[0033] FIG. 11 is a block diagram of the interwork router of the present invention.
[0034] FIG. 12 is a block diagram of a lower layer processing unit provided for the interwork router of the present invention.
[0035] FIG. 13 is a diagram of a VPN number table for receiving, provided in the lower layer processing unit of the present invention.
[0036] FIG. 14 is a block diagram of the lower layer processing unit provided in the interwork router of the present invention.
[0037] FIG. 15 is a diagram of a VPN number table for receiving, provided in the lower layer processing unit of the present invention.
[0038] FIG. 16 is a block diagram of a packet layer processing unit provided in the interwork router of the present invention.
[0039] FIG. 17 is a diagram of a route retrieval table/VPN table provided in the packet layer processing unit of the present invention.
[0040] FIG. 18 is a diagram of a header generating table provided in the lower layer processing unit of the present invention.
[0041] FIG. 19 is a diagram of the header generating table provided in the lower layer processing unit of the present invention.
[0042] FIG. 20 is a diagram showing an example of the interwork router in a network according to an embodiment of the present invention.
[0043] FIG. 21 is a diagram showing an example of the interwork router in a network according to an embodiment of the present invention.
[0044] FIG. 22 is a diagram showing an example of the interwork router in a network according to an embodiment of the present invention.
[0045] FIG. 23 is a diagram showing an interface for directing the interwork router from an NMS so as to set the tables in an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] Hereunder, various embodiments of the present invention will be described with reference to the accompanying drawings.
[0047] At first, a description will be made for how to compose a VPN over a plurality of ISPs, which are separated by a lower layer, respectively, according to the present invention, as well as the role of the interwork router of the present invention, with reference to FIGS. 1 and 2 . A lower layer as mentioned here is a protocol for encapsulating the header of each IP packet. This capsule header will also be described as a header of the lower layer even when each IP packet is encapsulated according to the IP header.
[0048] Hereunder, a description will be made of problems that will arise when a VPN is composed over a plurality of ISPs using a conventional router, with reference to FIG. 2 . In FIG. 2 , both ISP1 ( 2 - 1 ) and ISP2 ( 2 - 2 ) are interworking using a conventional router ( 9 ). The ISP1 and ISP2 are used to compose a VPN by encapsulating packets in a layer lower than the IP layer. The ISP1 provides services in the area A and includes LAN (Local Area Network) 1 ( 1 - 1 ), LAN2 ( 1 - 2 ), and LANa ( 1 - a ). The ISP2 provides services in the area B and includes LAN3 ( 1 - 3 ), LAN4 ( 1 - 4 ), and LANb ( 1 - b ). LAN1 to LAN4 belong to company A, which is planning to compose a VPN over those LANs. Both LANa and LANb belong to company B, which is different from company A and which is also planning to compose a VPN over those LANs. In such a case, if an encapsulation channel is provided between an inlet and an outlet of a network in the same ISP, packets of a specific user can be separated from packets of other users. A higher security network can thus be composed. However, if a VPN is to be composed over both ISP1 and ISP2, the conventional router terminates the lower layer at the interface on the input side and merges packets on the IP level, then executes the packet forwarding. And, this causes a problem in that packets from a plurality of users are mixed on the IP level. In other words, packets in a VPN are mixed with packets of other networks. Consequently, this makes it possible for malicious users to enter the network using false IP addresses. In addition, if two companies compose a LAN respectively using private addresses, each of those companies assigns its addresses independently. Thus, both of the companies might assign the same IP addresses. In such a case, the conventional router cannot transfer packets correctly due to conflict created by those addresses.
[0049] Next, how the present invention will solve the above problems will be described with reference to FIG. 1 . For example, assume now that the company A sends data from LAN1 to LAN3 of the same company A. In this embodiment, the ISP1 composes a VPN by encapsulating IP packets and the ISP2 composes a VPN by encapsulating packets in a MPLS network, which uses the ATM. Packets received by the ISP1 ( 2 - 1 ) from LAN1 are encapsulated as IP packets by the ISP1, and then they are received by the interwork router through the IP encapsulation logical channel ( 5 - 1 ). The interwork router ( 10 ) retrieves the output route from both of the IP-capsule header, indicating the IP encapsulation logical channel through which the object packet is received, and the header of the original packet, and then creates a new capsule header for the packet, which is to be used in the ISP2. In this embodiment, since the ISP2 provides services using MPLS, the interwork router creates an ATM header for the packet. Packets encapsulated by ATM are then transferred to LAN3 through the ATM logical channel ( 5 - 3 ). Since the interwork router retrieves the output route from both capsule header and IP header, it can transfer packets to the correct addresses even when both companies A and B use private addresses and a conflict occurs between IP addresses.
[0050] Although a description has been made of two encapsulating methods as encapsulating protocols in this embodiment, that is, IP encapsulation, which is an encapsulation method for the IP layer and ATM encapsulation, frame relay and HDLC protocols may also be used for such encapsulation.
[0051] Next, a description will be made of an embodiment of the present invention for a method of composing a VPN over a plurality of ISPs using a network configuration and a protocol stack, with reference to FIG. 3 . Any encapsulation protocol may be used in this embodiment. The ISP1 ( 2 - 1 ) is connected to LAN1 ( 1 - 1 ) and LAN2 ( 1 - 2 ) via edge nodes ( 3 - 1 and 3 - 2 ) respectively. In the same way, the ISP2 ( 2 - 2 ) is connected to a plurality of networks including LAN3 ( 1 - 3 ) and LAN4( 1 - 4 ) via edge nodes ( 3 - 3 and 3 - 4 ), respectively. Each of those ISPs encapsulates each of the IP packets using the header used inside the network between the inlet and the outlet of the network. Since the ISP assigns a capsule header to each of those IP packets uniquely to the subject VPN, the VPN traffic is identified among other traffic on the network, thereby enabling the VPN network to be a closed network. Both ISP1 ( 2 - 1 ) and ISP2 ( 2 - 2 ) interwork using the interwork router ( 10 ), thus the packets to the destination network are transferred via the interwork router ( 10 ).
[0052] For example, if a VPN (VPN1 in this case) connects both LAN1 and LAN2, each of the IP packets sent from LAN1 to LAN3 is retrieved according to the IP address at the edge node ( 3 - 1 ). At first, the packet is recognized to be addressed to the interwork router belonging to the VPN1, then a capsule header ( 103 a ) is added so that the packet is addressed to the interwork router belonging to the VPN1. The packet can thus be received correctly by the interwork router ( 10 ). The interwork router ( 10 ) retrieves the packet according to the capsule header ( 103 a ) and the IP address of each packet so as to be recognized as a packet addressed to the edge node ( 3 - 3 ) of the VPN1. Then, a capsule header ( 103 b ) is added to the packet so that it is addressed to the edge node ( 3 - 3 ) in the ISP2. The packet is thus transferred to the edge node ( 3 - 3 ) in the ISP2 according to the capsule header information. At the edge node ( 3 - 3 ), the capsule header is removed from the packet. The packet is then transferred to LAN3. Consequently, IP packets can be transferred in the VPN composed over the two networks so as to be prevented from mixing with packets belonging to other traffic.
[0053] IP packets, when they use global addresses, can be transferred just like they are transferred in the conventional networks, if both the destination (when capsule headers are used) and the capsule header of each packet are considered together without depending on the lower layer information.
[0054] Next, the operation of the interwork router ( 10 ) will be described with reference to FIGS. 4 to 6 . FIG. 4 shows a processing flow of a conventional router. FIGS. 5 and 6 show processing flows of the interwork router ( 10 ) of the present invention. The conventional router, when receiving packets, terminates the physical layer (step 201 ) used for transferring the packets in the ISP1 ( 2 - 1 ) and removes the capsule header used for the transfer operation in the ISP1 from each of those packets (step 202 ), and then it retrieves the route to the next network according to the value in the IP header of the packet (step 203 ). Then, the conventional router transfers the packets along the desired route via a switch (step 204 ). After that, the conventional router adds a capsule header to each of those packets used for the transfer operation in the ISP2 (step 205 ), and then it executes a processing for the physical layer (step 206 ) so as to output the packets from the transmission path. In this processing flow, since the capsule header of each packet used in the transfer operation in the ISP1 is removed and the route to the next ISP is determined only with the IP header of the packet, the traffic of a plurality of VPNs are merged once.
[0055] According to the interwork router of the present invention, however, such the problem can be avoided.
[0056] FIG. 5 shows an algorithm executed by the interwork router ( 10 ) of the present invention. According to the algorithm, if a packet arrives, the interwork router ( 10 ) terminates the physical layer used for the transfer operation in the ISP1( 2 - 1 ) (step 211 ), and then it retrieves the route to the ISP2 according to the capsule header and the IP header of the packet used in the transfer operation in the ISP1, thereby generating a new capsule header for the packet to be used in the ISP2 (step 212 ). After that, the router replaces the capsule header used in the ISP1 with the new capsule header (step 213 ), to be used in the transfer operation in the ISP2 (step 214 ), and then it transfers the packet to the switch. The packet is thus transferred by the switch into the desired route (step 215 ). After that, the router executes a processing for the physical layer (step 216 ) to output the packet from the transmission path. Consequently, the packet traffic can be separated from the traffic of other networks. In addition, since naked IP packets from which the capsule header is removed are never supplied to the switch, no other invalid users can insert packets in the VPN from this switch. In other words, it is impossible for invalid IP packets, which are not provided with an internal header used in the ISP2 respectively, are to be mixed with valid IP packets in the ISP2. Consequently, the security of the network is significantly improved.
[0057] Next, another embodiment of the present invention will be described with reference to FIG. 6 . The interwork router in this embodiment is provided with a table of correspondence between a set of capsule headers and IP header values used for the transfer operation in the ISP1 and capsule header indexes, as well as a table of correspondence between capsule header indexes and the capsule headers used for the transfer operation in the ISP2. The interwork router in this embodiment, if it receives a packet, terminates the physical layer used for the transfer operation in the ISP1 ( 2 - 1 ) (step 221 ). Then, the interwork router retrieves the route to the ISP2 according to the capsule header and the IP header of the packet, used for the transfer operation in the ISP1, and then it generates a capsule header index for the packet (step 222 ). After that, the router removes the capsule header used in the ISP1 from the IP packet and adds the generated capsule header index to the IP packet (step 223 ), and then it transfers the packet to the switch. The switch then transfers the IP packet into the determined route (step 224 ). Then, the router generates a capsule header to be added to the packet from the capsule header index (step 225 ). The generated capsule header is used in the transfer operation in the ISP2. The router then executes a processing for the physical layer (step 226 ) to output the IP packet from the transmission path. This interwork router configuration can also form a closed network with a high security just like that in the configuration shown in FIG. 5 . In other words, no invalid IP packet provided with no capsule header index is mixed with valid IP packets in the subject VPN.
[0058] Next, a description will be made as to how to compose a VPN over both the ISP1 for supporting the VPN using the MPLS method and the ISP2 for supporting the VPN using IP capsules, as well as an example of a packet configuration, with reference to FIGS. 7 to 10 .
[0059] FIG. 7 shows an example of a network configuration and protocol stacks. Although no encapsulation method is defined specially in the description with reference to FIG. 3 , FIG. 7 shows an embodiment in which the ISP1 employs the MPLS method and the ISP2 employs an IP encapsulation method. The interwork router ( 10 ) forwards packets by using a combination of the ATM layer ( 104 a ), which is equivalent to a capsule header just like in FIG. 3 , with the IP layer ( 101 ) and a combination of the IP capsule layer ( 104 b ) with the IP layer ( 101 ). Consequently, the router ( 10 ) can forward packets correctly even when addresses are duplicated due to the private addresses used by each of the VPNs.
[0060] Hereunder, a method of encapsulating IP packets in an ATM will be described with reference to FIG. 8 . This encapsulation is standardized by RFC1483 of IETF. At first, an LLC/SNAP (Logical Link Control/Subnetwork Attachment Point) ( 253 ) is added to each IP packet comprising an IP header ( 250 ) and an IP payload ( 251 ), then an AAL (ATM Adaptation Layer) 5 header ( 252 ) and an AAL5 trailer ( 255 ) are added to the IP packet, thereby composing an AAL5 frame. A PAD ( 254 ) is then inserted in the AAL5 frame so as to make the AAL5 frame become a constant multiple of 48 octets, which is the length of the ATM cell payload ( 257 ). This AAL5 trailer is then divided into ATM cells in units of 48 octets and an ATM header ( 256 ) is added to each of the divided ATM cells. The IP packet is thus transferred as one or a plurality of ATM cells.
[0061] FIG. 9 shows the IPv (Internet Protocol Version) 4 packet format indicated by RFC (Request for Comments) 791. When encapsulating an IP packet, the encapsulation protocol uses the Ipv4 header as is. The conventional Ipv4 router in the subject network can also be used as the router.
[0062] FIG. 10 shows a method of encapsulation by the IP tunnel indicated by RFC 1853. This method encapsulates each IP packet comprising an IP header ( 260 ) and an IP payload ( 261 ) transferred from a user according to the capsule header ( 264 ). This capsule header comprises an IP header ( 262 ) and a tunnel header ( 263 ). This capsule header is used in the ISP2 and it can be identified uniquely in the subject network. Consequently, even when the subject user uses a private address, each IP packet is routed using the capsule header in the network. The IP packet can thus be transferred to the desired edge node. In this embodiment, a tunnel header generated by RFC1583 is taken as an example, but GRE (Generic Routing Encapsulation) encapsulation (RFC1792), IP mobile, and other methods may also be used for encapsulating IP packets.
[0063] The interwork router ( 10 ) combines the capsule header of each packet shown in FIGS. 8 and 10 with the IP address of the user for forwarding the IP packet. Thus, the VPN can be composed with a high security over a plurality of ISPs. The user can also use private addresses so as to compose such a VPN.
[0064] Next, an embodiment of the interwork router ( 10 ) will be described with reference to FIGS. 11 to 19 .
[0065] FIG. 11 shows a configuration of the interwork router ( 10 ). The control unit ( 50 ) is used for controlling the whole router ( 10 ) and for routing packets to other nodes. The core switch ( 51 ) is a switch for transferring packets between packet layer processing units ( 52 ). The lower layer processing unit (ATM) ( 53 ) is an interface for connecting to the MPLS network of the ISP1, and the lower layer processing unit (IP capsule) ( 54 ) is an interface for connecting to the IP capsule network of the ISP2. The packet layer processing unit ( 52 ) receives both lower layer information and each IP packet from the lower layer processing units ( 53 and 54 ) and determines the destination of the packets according to the combination of the lower layer information and the header information of the IP packet.
[0066] At first, the flow of the receiving processing will be described. FIG. 12 shows a block diagram of the lower layer processing unit (ATM) ( 53 ). For the signal received from the ISP1 network, the physical layer is terminated at the physical layer processing unit ( 150 ), then the ATM layer is terminated at the ATM layer processing unit ( 151 ). At this time, the ATM header used to identify the VPN for receiving is also transferred to the VPN number adding unit ( 152 ) together with the recomposed IP packet. The VPN number adding unit ( 152 ) generates a VPN number which is used to identify the object VPN in the router from the ATM header of the IP packet. At this time, the VPN number table for receiving ( 153 ) is used. This VPN number and the IP packet are then transferred together to the packet layer processing unit via the packet processing unit IF ( 154 ).
[0067] FIG. 13 shows a configuration of the VPN number table for receiving ( 153 ). This table ( 153 ) comprises pairs of the ATM header in input side ( 300 ) and the VPN number in input side ( 303 ). The ATM header on the input side is used as an input key for outputting a VPN number on the input side ( 303 ). In addition to the VPI/VCI (Virtual Path Identifier/Virtual Channel Identifier) ( 301 ), the ATM header on the input side used as an input key may also be the CLP (Cell of Priority) bit ( 302 ) indicating the priority of the packet transfer. In addition to the internal VPN number ( 304 ), the field of the internal VPN number on the input side may also be provided with another field ( 305 ) for the QoS (Quality of Service). A table for mapping CLP and QoS may also be provided independently of this table for identifying each of the VPNs.
[0068] FIG. 14 shows a block diagram of the lower layer processing unit (IP capsulation) ( 54 ). For the signal received from the ISP2, the physical layer is terminated at the physical layer processing unit ( 170 ), and then the capsule header is terminated at the capsule layer receiving processing unit ( 171 ). At this time, the terminated capsule header is transferred together with the IP packet to the VPN number adding unit ( 172 ). The VPN number adding unit ( 172 ) generates a VPN number used to identify respective internal VPNs from the ATM header. At this time, the VPN number table for receiving ( 173 ) is used. This VPN number and the IP packet are transferred to the packet layer processing unit via the packet processing unit IF (Interface) ( 154 ).
[0069] FIG. 15 shows a configuration of the VPN number table for receiving ( 153 ). This table comprises pairs of the capsule header on the input side ( 310 ) and the VPN number on the input side ( 303 ). The ATM header on the input side is used as an input key for outputting the VPN number on the input side ( 303 ). In addition to the source address ( 311 ) of the capsule header, the IP capsule header on the input side used as an input key may also be the TOS (Type of Service) field ( 302 ) for a packet transfer priority. And, in addition to the internal VPN number ( 304 ), the internal VPN number on the input side may also be provided with a field ( 305 ) indicating the QoS.
[0070] In addition, another table for mapping both ToS and QoS may be provided so as to identify VPNs independently of this table.
[0071] Next, a description will be made of a processing executed when an VPN number on the input side ( 303 ) and an IP packet arrive at the packet layer processing unit ( 52 ) using the method described with reference to FIGS. 12 to 15 . FIG. 16 will be referenced for this description. Receiving the VPN number on the input side ( 304 ) and the IP packet through the lower layer processing unit ( 180 ), the route retrieval table/VPN table ( 181 ) retrieves the route to the next network according to the keys (IP header and VPN number on the input side) using the route retrieval table/VPN table ( 182 ) and determines a VPN number on the output side. Consequently, the output route, the VPN number on the output side, and the IP packet are transferred to the core switch via the core switch IF, and then they are received by the desired packet layer processing unit.
[0072] FIG. 17 shows a configuration of the route retrieval table/VPN table ( 182 ). Both the VPN number on the input side ( 320 ) and the IP header ( 323 ) are used as keys for retrieval processing so as to output both output route number ( 325 ) and the capsule number on the output side ( 326 ). The output route number ( 326 ) is an internal identifier used to transfer packets to a desired interface via both a core switch and other devices. The capsule number on the output side ( 326 ) is an internal identifier used to add a capsule header to each packet in the lower layer processing unit. The capsule number on the output side ( 326 ) may also be provided with a QoS ( 328 ) in addition to the capsule number ( 327 ) so as to control transfer priorities.
[0073] The operation of the packet layer processing unit ( 52 ) illustrated in FIG. 11 will be as follows with respect to a decision as to a transmission direction, as shown in FIG. 16 . Receiving both a capsule number on the output side ( 326 ) and an IP packet via the core switch IF ( 184 ), the packet layer processing unit 52 transfers these information items to the lower layer processing units ( 53 and 54 ) illustrated in FIG. 11 through the lower layer processing unit IF.
[0074] The operation of the lower layer processing unit (ATM) ( 53 ) will be as shown in FIG. 12 . The lower layer processing unit (ATM) ( 53 ) receives both the capsule number on the output side ( 326 ) and IP packet from the packet layer processing unit ( 52 ) via the packet layer processing unit IF ( 159 ). Then, the ATM header deciding unit ( 157 ) generates an ATM header corresponding to the capsule header from the capsule number on the output side ( 326 ) with reference to the header generating table ( 158 ). The ATM header generated in such a way and the IP packet are converted into ATM cells in the ATM layer transmission processing unit ( 156 ), and then the ATM cells are transferred to the ISP1 network via the physical layer transmission processing unit ( 155 ).
[0075] FIG. 18 shows a configuration of the header generating table. The header generating table outputs an ATM header on the output side according to each capsule number on the output side used as a key. The object ATM header on the output side can thus be obtained from the capsule number on the output side.
[0076] In the same way, the operation of the lower layer processing unit (IP capsule) ( 54 ) will be as shown in FIG. 14 . The lower layer processing unit (IP capsule) ( 54 ) receives both a capsule number on the output side ( 326 ) and an IP packet from the packet layer processing unit ( 52 ) illustrated in FIG. 11 via the packet layer processing unit IF ( 159 ). Then, the capsule header deciding unit ( 177 ) illustrated in FIG. 14 generates an IP capsule header corresponding to the capsule header and a MAC address on the output side from the capsule number on the output side ( 326 ) with reference to the header generating table ( 178 ) illustrated in FIG. 14 . The IP capsule header and the MAC (Media Access Control) address on the output side generated in such a way, as well as the IP packet, are encapsulated in the capsule layer transmission processing unit ( 176 ), and then they are transmitted to the ISP1 network via the physical layer transmission processing unit ( 175 ) illustrated in FIG. 14 .
[0077] FIG. 19 shows a configuration of the header generating table ( 178 ). The header generating table outputs both an IP capsule header on the output side and a MAC address on the output side according to each capsule number on the output side used as a key.
[0078] This completes the description of the configuration of the interwork router. In this embodiment, an VPN number on the input side ( 320 ) and a capsule number on the output side ( 326 ) that are unified in the router are used for each processing on the input side and output side. However, a capsule header on the input side may be used as an input key of the route retrieval table/VPN table and a capsule header on the output side may be generated directly as an output.
[0079] The tables shown in this embodiment are all logical tables. It is thus possible to employ a table retrieval method, which retrieves an address using a retrieval algorithm represented by a tree hierarchy, thereby obtaining a desired output, as well as to employ a CAM (Channel Access Method) configuration and a sequential table retrieval method.
[0080] FIG. 23 shows a configuration of an MIB (Management Information Base), which is an interface for outputting commands from an NMS to the interwork router, and an agent is mounted in the control unit 50 so as to set the tables in this embodiment. The capsule header entry on the input side ( 500 ) is an MIB for setting the VPN table for receiving, as shown in FIG. 13 . In the same way, the VPN cross connector entry ( 501 ) is an MIB for setting the route retrieval table/VPN table ( 182 ) shown in FIG. 17 . In the same way, the capsule header entry on the output side ( 502 ) indicates a configuration of the header generating table. The information set in those MIBs is set by the NMS for the control unit ( 50 ), and then it is set by the control unit ( 50 ) in each unit of the interwork router.
[0081] So far, a description has been made mainly for a configuration of the interwork router used for a plurality of VPNs. Hereunder, how such an interwork router will be used in a network will be described with reference to FIGS. 20 to 22 .
[0082] FIG. 20 shows an example of connecting two ISPs to each other via two interwork routers belonging to those two ISPs. Each of those two VPNs is identified according to the header of each packet transferred between those two interwork routers. Each of the interwork routers ( 10 a and 10 b ) determines the route of packets according to the combination of a capsule header ( 103 a , 103 b , or 103 c ) and an IP address as described with reference to FIGS. 1 through 19 .
[0083] FIG. 21 shows an example of connecting two ISPs to each other via an IX used for layer 3 processing. Each of those two ISPs is provided with an interwork router. Each VPN is identified between each interwork router and the IX according to the capsule header of each packet ( 103 b ). Each of the interwork router ( 10 a ), the IX ( 10 c ), and the interwork router ( 10 b ) forwards each packet according to the combination of the capsule header ( 103 a , 103 b , or 103 c ) and the IP address as described with reference to FIGS. 1 through 19 .
[0084] FIG. 22 shows an example of connecting two ISPs to each other via an IX. Each of those two ISPs is connected to an interwork router. The IX in this example is composed of a layer 2 unit, which does not execute layer 3 processing. Also in this case, each VPN is identified between each interwork router and the IX according to the capsule header of each packet ( 103 b ). Each of the interwork routers ( 10 a and 10 b ) forwards each packet according to the combination of the capsule header ( 103 a , 103 b , or 103 c ) and the IP address, as described with reference to FIGS. 1 through 19 . The IX transfers packets through layer 2 forwarding processing.
[0085] Although a description has been made as to how to connect a VPN over a plurality of ISPs, such a VPN connection is also needed for the same node configuration even when a plurality of encapsulation areas exist in the same ISP. In such a case, the VPN can be connected to those ISPs using the method of the present invention.
[0086] According to the present invention, therefore, a VPN network can be composed over a plurality of ISPs as described above. In addition, QoS information can be interworked among a plurality of VPN networks.
[0087] Although the present invention has been described in connection with a preferred embodiment thereof, many other variations and modifications will be apparent to those skilled in the art. | A data communication apparatus to be coupled to a first network and a Multiprotocol Label Switching (MPLS) network, includes a receiving unit which receives a data including header information indicating a destination and first header information used to identify a first Virtual Private Network (VPN) in the first network. The apparatus also includes a transmitter which transmits data having added thereto a MPLS header information used to identify one of the plurality of second VPNs in the MPLS network, the MPLS header information corresponding to both the header information indicating the destination and the first header information used to identify the first VPN in the first network included in the received data. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This claims priority from U.S. Provisional Application No. 62/202 343, filed Aug. 7, 2015, the disclosure of which is hereby incorporated by reference in its entirety into this application.
FIELD OF THE INVENTION
[0002] The invention relates to a planar structure from a plurality of folding portions which are interconnected by way of integral hinges and which are erectable to a functional position so as to form a three-dimensional body.
BACKGROUND OF THE INVENTION
[0003] A planar structure of this type in the form of a cover for a cargo-space floor is known from DE 198 10 714 A1. The cover has a water-tight integral planar structure. The planar structure is provided with flexible folding portions which have a central part and lateral parts which are disposed so as to be distributed around the central part. The lateral parts surrounding the central part may be erected to form an ashlar-shaped container. Respective fixing means serve for mutually fixing the lateral parts in the erected functional state. In a spread-out covering position all folding portions are disposed in one plane such that the flat planar structure thus designed may be used as a protective mat for a cargo-space floor.
SUMMARY OF THE INVENTION
[0004] It is an object of the invention to achieve a planar structure of the type mentioned at the outset which enables a supporting function for cargo on a cargo-space floor of a motor vehicle.
[0005] This object is achieved in that the folding portions are of a triangular design in such a manner that the folding portions are erectable to form a supporting corner in the form of a triangular pyramid. The triangular pyramid herein is of open design such that the supporting corner can receive a corner region of a cargo such as of a carton, a box, or similar. The supporting corner has the effect of positionally securing a respective item to be transported in a cargo space. In a particularly advantageous manner, a plurality of planar structures according to the invention are provided so as to, by being erected in the functional position, form a plurality of supporting corners which in relation to the cargo tray may support items to be transported in the form of an ashlar, a box, or similar, on a plurality of sides. When not in use, the supporting corner may be spread out in a simple manner so as to form the planar structure such that said supporting corner may be accommodated in a space-saving manner on the cargo-space floor or on another point of the cargo space or of a vehicle interior of the motor vehicle. The supporting corner in the form of the open triangular pyramid represents an open tetrahedron.
[0006] In a design embodiment of the invention, the folding portions are at least partially provided with reinforcement plates. The reinforcement plates are preferably inserted between film regions of the folding portions and fixed between these film skins which are composed of plastics.
[0007] In a further design embodiment of the invention, a floor-side folding portion is provided with an anti-slip layer. The anti-slip layer may be configured in various forms. Said anti-slip layer may be formed by a rubber or elastomer layer of continuous or mutually spaced apart rubber or elastomer portions. Alternatively, said anti-slip layer may be formed by bonding means in the form of hook-and-pile elements, in the form of adhesive layers, or similar. It is essential for the anti-slip layer that a high level of static friction is achieved in relation to the surface of the cargo-space floor.
[0008] In a further design embodiment of the invention, bonding elements, in particular in the form of hook-and-pile elements, magnetic elements, adhesive elements, are provided. The bonding elements are capable of being manually converted to the fixing position or to the releasing position of the former.
[0009] Further advantages and features of the invention are derived from the claims and by means of the following description of preferred exemplary embodiments of the invention, which are illustrated by means of the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 schematically shows a cargo on a floor of a cargo space of a motor vehicle, said cargo being supported by four planar structures as per an embodiment according to the invention;
[0011] FIG. 2 in an enlarged perspective illustration shows a planar structure according to FIG. 1 , which has been erected to form a piece corner;
[0012] FIG. 3 shows the planar structure as per FIG. 2 in a spread-out standby position;
[0013] FIGS. 4 to 6 show the planar structure as per FIGS. 2 and 3 in various positions during conversion from the standby position to the erected functional position;
[0014] FIG. 7 shows a further embodiment of a planar structure according to the invention, similar to that of FIG. 3 ;
[0015] FIG. 8 shows a further embodiment of a planar structure according to the invention;
[0016] FIGS. 9 to 12 show the planar structure as per FIG. 8 in various positions during conversion of the planar structure from the standby position to the erected functional position ( FIG. 12 );
[0017] FIG. 13 shows a further embodiment of a planar structure according to the invention, in a spread-out standby position;
[0018] FIGS. 14 and 15 show the planar structure as per FIG. 13 , in various folded positions; and
[0019] FIG. 16 shows a further embodiment of a planar structure according to the invention, similar to that of FIG. 4 , in a partially erected folded position.
DETAILED DESCRIPTION
[0020] A cargo space L of a passenger motor vehicle has a cargo-space floor B which at mutually opposite sides is delimited by side walls. Toward the front, the cargo-space floor B is delimited in a manner not illustrated in more detail by a seatback assembly of a passenger cabin. Toward the rear, delimitation of the cargo-space floor B is performed by a rear end of the passenger motor vehicle, said rear end being potentially designed so as to be movable as a tailgate, or as to be static. Four supporting corners 1 , each representing one planar structure in the context of the invention, are provided for positionally securing an in particular ashlar-shaped or box-shaped item to be transported T on the cargo-space floor B. The four supporting corners 1 are provided on four floor-side corner regions of the item to be transported T, wherein the supporting corners 1 are laterally pushed from the outside onto these corner regions until folding portions 2 to 4 (to be described in more detail hereunder) of the respective supporting corner 1 are in contact with the respective wall portions of the item to the transported T in these corner regions.
[0021] According to FIGS. 2 to 6 , each supporting corner 1 is formed by a planar structure which in the spread-out standby position ( FIG. 3 ) lies flat on a cargo-space floor B or on another support and which is of rectangular, presently square, design. The planar structure which forms the supporting corner 1 in FIG. 3 is viewed from a rear side. The planar structure has a first folding portion in the form of a base portion 2 , and two further folding portions in the form of two lateral portions 3 , 4 . The lateral portions 3 , 4 , as well as the base portion 2 , are in each case of triangular design. The lateral portions 3 , 4 , on mutually longitudinal sides of the base portion 2 , are connected by a folding arrangement in the form of an integral hinge F to the base portion 2 . Moreover, the planar structure has two folding portions 5 , 6 which serve for fixing the supporting corner 1 in the erected functional position thereof according to FIGS. 2 and 6 . The folding portions 5 and 6 are likewise of triangular design. The latter however only have half the area of the lateral portions 3 , 4 and of the base portion 2 . The two folding portions 5 and 6 are interconnected by a fold line. Moreover, according to FIG. 3 , the latter are connected to the lateral portions 3 , 4 by way of fold lines (not referred to in more detail) in the form of integral hinges.
[0022] As is indicated by means of FIG. 3 , the base portion 2 in the region of the lower side thereof has an anti-slip layer 7 which in the exemplary embodiment illustrated is embodied as a rubber or elastomer layer. The lower side in the illustration as per FIG. 3 lies on top.
[0023] Moreover, according to FIGS. 1 to 6 , the planar structure which is erectable to form the supporting corner 1 in the region of the one folding portion 5 and in the region of the lateral portion 4 is provided with fixing means 8 which in the exemplary embodiment illustrated are designed as hook-and-pile elements.
[0024] According to FIGS. 2 and 6 , erecting the planar structure to form the supporting corner 1 is performed according to the illustrations as per FIGS. 4 and 5 . The two lateral portions 3 , 4 are first erected in relation to the base portion 2 . Herein, the two folding portions 4 , 6 are folded outward toward the rear side and are folded on top of one another. Herein, the hook-and-pile element of the folding portion 5 is brought to a position which is directly adjacent to the hook-and-pile element which is disposed on the outside on the lateral portion 4 , such that the folding portions 5 and 6 which are folded together to form the overlapping triangle are fixed on the outside to the lateral portion 4 . On account thereof, the erected functional position of the supporting corner 1 is achieved and secured.
[0025] The base portion 2 as well as the lateral portions 3 and 4 are provided with reinforcement plates which are integrated in the respective folding portions. Preferably, the folding portions 2 to 4 are formed by plastics films which each represent one external skin and one internal skin. The respective reinforcement plate is inserted between the external skin and the internal skin. The external skin and the internal skin are welded to one another at the peripheral regions of the reinforcement plate. The reinforcement plates are of triangular design, in an analogous manner to the folding portions 2 to 4 . No reinforcement plates are provided in the region of the integral hinges F, so as not to impede the flexibility of the integral hinges F. The integral hinges are formed by external and internal skins of the plastics films in that the external and internal skin are welded to one another in this region.
[0026] The embodiments as per FIGS. 7 to 16 correspond substantially to the embodiment which has been described above by means of FIGS. 1 to 6 . Therefore, parts and portions having equivalent functions are provided with the same reference signs having index letters a or b, respectively, or c and d, respectively. The supporting corners 1 a, 1 b, 1 c, and 1 d, according to FIGS. 7 to 16 , are also provided for positioning on a cargo-space floor B, in an analogous manner to FIG. 1 . The folding portions 2 a to 4 a, and 2 b to 4 b, and 2 c to 4 c, and 2 d to 4 d, are provided with triangular reinforcement plates in the same manner as is the case with the embodiment as per FIGS. 1 to 6 . The integral hinges F or fold lines, respectively, are embodied in an identical manner. The points of difference of the embodiments according to FIGS. 7 to 16 will be discussed hereunder.
[0027] It is a substantial point of difference in the case of the supporting corner 1 a as per FIG. 7 , that the planar structure indeed has a base portion 2 a and two lateral portions 3 a, 4 a, which are configured in a substantially identical manner to the folding portions in the case of the embodiment according to FIGS. 1 to 6 . However, the planar structure has only one single further folding portion 5 a which is articulated only on the one lateral portion 3 a by way of a respective integral hinge. The lateral portion 4 a on the external side has a fixing means 8 a which is designed as a hook-and-pile element. The folding portion 5 a on the internal side has a complementary hook-and-pile element as a fixing means 8 a. Once the lateral portions 3 a, 4 a are folded up, the folding portion 5 a is pressed from the outside onto the lateral portion 4 a, on account of which the fixing means 8 a are brought into mutual contact, securing the erected functional position.
[0028] The supporting corner 1 b as per FIGS. 8 to 12 also corresponds substantially to the embodiments which have been described above. It is a substantial point of difference in the case of the supporting corner lb that the planar structure beside the base portion 2 b and the two lateral portions 3 b and 4 b has two folding portions 5 b, 6 b, of which only the one folding portion 6 b is connected directly to the lateral portion 3 b. By contrast, the other folding portion 5 b is connected only to the folding portion 6 b. The folding portions 5 b and 6 b, in a manner analogous to the folding portions 5 , 6 , and to the folding portion 5 a, are provided with dimensions which are halved in relation to the lateral portions 3 b, 4 b.
[0029] In the case of the supporting corner 1 b the lateral portion 4 b on the internal side is provided with a fixing means 8 b in the form of a hook-and-pile element. The folding portion 5 b is provided with a complementary fixing means 8 b in the form of a corresponding hook-and-pile element. During erection of the two lateral portions 3 b, 4 b the folding portion 6 b at the rear side is folded onto the external side of the lateral portion 4 b, wherein a fold line between the two folding portions 5 b, 6 b is axiomatically aligned so as to be flush with an upper edge of the lateral portion 4 b. Subsequently, according to FIGS. 11 and 12 , the folding portion 5 b may be folded over from above toward the internal side of the lateral portion 4 b, on account of which the fixing means 8 b come into mutual contact. On account thereof, the erected functional position of the supporting corner 1 b is achieved and secured.
[0030] In the case of the supporting corner 1 c as per FIGS. 13 to 15 , a total of four folding regions which are embodied as the base portion 2 c, as the lateral portions 3 c, 4 c, and as the folding portion 5 c, are provided. The base portion 2 c and the first lateral portion 3 c are interconnected by way of a fold line in the form of an integral hinge F. The two lateral portions 3 c and 4 c are also interconnected by way of an integral hinge f. The folding portion 5 c by way of a further folding line in the form of an integral hinge F is connected to a lateral periphery of the lateral portion 4 c. However, this folding portion 5 c by way of a slot is separated from the base portion 2 c, the latter in the spread-out standby position according to FIG. 13 is adjacent to the left of the former. Both the base portion 2 c as well as the folding portion 5 c have fixing means 8 c each on the upper side and on the lower side. Alternatively, it is possible for fixing means 8 c to be provided only on an upper side or lower side in the case of each the base portion 2 c and in the case of the folding portion 5 c, said fixing means 8 c then having to be disposed such that, depending on the folding strategy, they come into mutual contact. Therefore, when the folding portion 5 c is applied to the upper side of the base portion 2 c, the lower side of the folding portion 5 , and the upper side of the base portion 2 c, each have to be provided with one fixing means 8 c. Conversely, if the folding portion 5 c is to be fixed to the base portion 2 c from below ( FIG. 15 ), then the folding portion 5 c in the region of the upper side, and the base portion 2 c in the region of the lower side, are provided with a respective fixing means 8 c.
[0031] In the embodiment illustrated, in the case of which fixing means 8 c are provided on both sides, an operator may perform folding according to FIG. 14 or alternatively folding according to FIG. 15 . Secure fixing of the folding portion 5 c in relation to the base portion 2 c is achievable in both cases.
[0032] The supporting corner 1 d according to FIG. 16 corresponds substantially to the supporting corner 1 as per FIG. 4 . The only point of differentiation is that in the case of the supporting corner 1 d the folding portion 6 d on the internal side is provided with a fixing means 8 d, whereas the folding portion 5 d has no fixing means. The lateral portion 4 d on the external side is provided with a complementary fixing means which is not illustrated by means of FIG. 16 . The folding portion 5 d is cut out such that the folding portion 6 d, which during folding is on the external side, may come into direct contact with the external-side fixing means of the lateral portion 4 d. On account thereof, simplified and more compact fixing of the supporting corner 1 d than in the case of the embodiment according to FIG. 4 is achievable.
[0033] Since the fixing means 8 , 8 a, 8 b, 8 c, 8 d in the case of all embodiments are embodied so as to be releasable, the supporting corners 1 , 1 a, 1 b, 1 c, 1 d may be converted in the same manner from the erected functional position thereof back to the spread-out standby position thereof in which said supporting corners 1 , 1 a, 1 b, 1 c, 1 d result in the flat planar structures according to FIGS. 3, 7, 8, and 13 . | A planar structure formed from a plurality of folding portions which are interconnected by way of integral hinges and which are erectable to a functional position so as to form a three-dimensional body. A fixing arrangement is provided for mutually fixing the folding portions in the erected functional position. The folding portions are of triangular design such that the folding portions are erectable to form a supporting corner in the form of a triangular pyramid. The structure can be utilized in the cargo space of passenger motor vehicles. | 1 |
BACKGROUND OF THE INVENTION AND INFORMATION DISCLOSURE STATEMENT
This invention relates generally to an electrophotographic copying apparatus, and more particularly, to the heat and pressure fixing of toner images formed on a copy substrate by direct contact with a heated fusing member.
In the process of xerography, a light image of an original to be copied is typically recorded in the form of a latent electrostatic image upon a photosensitive member with subsequent development of the latent image by the application of marking particles commonly referred to as toner. The visual toner image is typically transferred from the member to a copy substrate, such as a sheet of plain paper, with subsequent affixing of the image by one of several fusing techniques. A preferred fusing system applies both heat and pressure to the copy substrate.
In one prior art fusing system, a fuser roll is used which has an outer surface or covering of polytetrafluoroethylene or silicone rubber, the former being known by the trade name Teflon, to which a release agent such as silicone oil is applied, the thickness of the Teflon being on the order of several mils and the thickness of the oil being less than 1 micron. Silicone based oils which possess a relatively low surface energy, have been found to be materials that are suitable for use in a heated fuser roll environment where Teflon constitutes the outer surface of the fuser roll. In practice, a thin layer of silicone oil is applied to the surface of the heated roll to form an interface between the roll surface and the toner images carried on the support material. Thus, a low surface energy layer is presented to the toner as it passes through the fuser nip and thereby prevents toner from offsetting to the fuser roll surface. A fuser roll construction of this type is disclosed in U.S. Pat. No. 3,718,116 assigned to Xerox Corporation.
While heat and pressure fusers of the type discussed above are desirable because of their thermal efficiency, they possess some disadvantages because of their mechanical complexity, cost, long warm-up times and paper wrinkling. A second type of system is known in the prior art which reduces or eliminates these undesirable characteristics. This system utilizes a relatively low mass fuser roll member of the type disclosed, for example, in U.S. Pat. No. 4,689,471 assigned to Xerox Corporation. As disclosed in this patent, a low mass heated fuser roll cooperates with an elongated web member comprising a woven fabric to form an extended fusing area. One end of the pressure web is fixed while the other end is biased into pressure engagement with the fuser roll to form an entrance nip. The pressure web is an enabling feature of this type of system but its effectiveness depends upon several factors such as the type of copy substrate media being used and relative humidity conditions. As an example, certain types of copy media are as subject to stalling or jamming on the leading edge entrance of the fuser entrance nip. The pressure and location of the biasing means if therefore of critical importance. One improvement is disclosed in U.S. Pat. No. 4,860,047 in which a feed roller is introduced at the entrance nip which cooperates with the fuser roll to improve entrance of the copy sheet into the fusing area.
The present invention is directed to a still further improved system whereby a copy sheet entry into the fusing area is effected by causing the fuser web member to move in the direction of copy sheet movement at the critical moment of entry carrying the leading edge of the copy sheet into the entrance nip area. More particularly the invention relates.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view in section of a reproduction machine having the improved fuser system of the present invention.
FIG. 2 is an enlarged view of a first embodiment of the fuser system shown in FIG. 1.
FIG. 3 is an enlarged view of a second embodiment of the fusing system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 of the drawings there is shown a xerographic type reproduction machine 8 incorporating the present invention. Machine 8 has a suitable frame 12 on which the machine xerographic components are operatively supported. Briefly, as will be familiar to those skilled in the xerographic printing and copying arts, the xerographic components of the machine include a charge retentive recording member, shown here in the form a of a rotatable photoreceptor 14. In the exemplary arrangement shown, photoreceptor 14 comprises a drum having a photoconductive surface 16. Other photoreceptor types such as belt, web, etc. may instead be employed. Operatively disposed about the periphery of photoreceptor 14 are a charging station 18 with charge corotron 19 for placing a uniform charge on the photoconductive surface 16 of photoreceptor 14, exposure station 22 where the previously charge photoconductive surface 16 is exposed to image rays of a document 9 being copied or reproduced to thereby form a latent electrostatic image on the charge retentive surface; development station 24 where the latent electrostatic image created on photoconductive surface 16 is developed by toner; combination transfer and detack station 28 with transfer corotron 29 detack corotron 30 for sequentially transferring the developed image to a suitable copy substrate material such as a copy sheet 32 brought forward in timed relation with the developed image on photoconductive surface 16 and lessening the forces of attraction between the copy substrate and the charge retentive member; cleaning station 34 and discharge corotron 36 for removing leftover developer from photoconductive surface 16 and neutralizing residual charges thereon.
A copy sheet 32 is brought forward to transfer station 28 by feed roll pair 40. Sheet guides 42, 43, serve to guide the sheet through an approximately 180 degree turn prior to the copy substrate reaching the transfer station 28. Following transfer, the sheet 28 is carried forward to a fusing station 44 where the toner image is contacted by fusing roll 49 forming one member of a heat and pressure fuser. Fusing roll 49 is heated by a suitable heater such as quartz lamp 50 disposed within the interior of roll 49. After fusing, the copy sheet 32 is discharged from the machine.
A transparent platen 50 supports the document 9 as the document is moved past a scan area 52 by a constant velocity type transport 54. As will be understood, scan area 52 is in effect a scan line extending across the width of platen 50 at a desired point along platen 50 where the document is scanned line by line as the document is moved along platen 50 by transport 54. Transport 54 has input and output document feed roll pairs 55, 56 respectively on each side of scan area 52 for moving document 9 across platen 50 at scan area 52. The image rays from the document line scanned are transmitted by a gradient index fiber lens array 60 to exposure station 22 to expose the photoconductive surface 16 of the moving photoreceptor 14.
Developing station 24 includes a developer housing 65, the lower part of which forms a sump 66 for holding a quantity of developer 67. As will be understood by those skilled in the art, developer 67 comprises a mixture of larger carrier particles and smaller toner or ink particles. A rotatable magnetic brush developer roll 70 is disposed in a predetermined cooperative relation to the photoconductive surface 16 in developer housing 65, roll 70 serving to bring developer from sump 66 into developing relation with photoreceptor 14 to develop the latent electrostatic images formed on the photoconductive surface 16.
The fuser roll 49 comprises a thin-walled thermally conductive tube having a thin (i.e. approximately 0.005 inch (0.01 Centimeters)) coating of silicon rubber on the exterior surface thereof which contacts the toner images on the copy substrate to thereby affix the images to the substrate. A release agent management system, not shown, applies a thin layer of silicone oil to the surface of the fuser roll for the prevention of toner offset thereto as well as reducing the torque required to effect rotation of the fuser roll. In one operative embodiment of the fuser roll its diameter was 3.3 inches and had a length of 40 inches. This embodiment is typically used to fuse images on copy substrates that are 3 feet (0.91 meters) wide by 4 feet (1.22 meters) in length.
The fuser apparatus 44 also comprises a non-rotating, elongated pressure web member 72. As viewed in FIGS. 1 and 2, one end of web 72 is wrapped around reciprocating drive pulley 74. The opposite end of the web is biased into engagement with the fuser roll so that the fuser roll and the web cooperate to form an elongated nip 78 therebetween.
A pressure applying mechanism 80 creates a force between the roll and web so as to produce a frictional force therebetween that keeps the web in tension so it can provide suitable pressure to the surface of the fuser roll. Mechanism 80 encompasses a weighted rod 82 disposed in a loop 84 formed in web 72. A portion of the web intermediate the two ends thereof rides over a curved portion 86 of a web frame or support member 88. A biasing force is applied to the frame or support member 88 so that to thereby urge the web 72 into engagement with the fuser roll 49. The force, so applied, is just sufficient to keep the web biased against the roll in the fusing zone.
A blade member 90 has one end anchored in the frame structure 92 while its other end contacts the web at the nip area 93 to apply a load against the web and thereby cooperate with the pressure applying mechanism 80 to effect the required pressure in the nip for satisfactory operation. The area of contact between the web and the fuser roll forms the entrance to the nip area. The blade is preferably fabricated from thermally nonconductive material and is mounted such that in its free state it is flat and in its operative state the edge of the blade is deflected by the fuser roll to thereby cause it to function as a leaf spring, applying the aforementioned load against the web. Edge contact of the blade produces the highest possible pressure for a given force or lead the purpose of the blade is to control paper cockle caused by the rapid drying of high moisture content paper.
According to a first aspect of the invention, reciprocating pulley 74 is adapted to rotate in a counterclockwise direction when the leading edge of copy sheet 32 begins its entrance into nip area 93. Appropriate signals are generated from system controller 95 and sent to drive motor 98. Gear output shaft 100 cooperates with gear 102 to drive pulley 74 in the counterclockwise direction for a relatively short time duration. As the pulley rotates, web member 72, moving in the same direction as copy sheet 32, frictionally engages the copy sheet against the surface of fuser roll 49, carrying it into and just beyond the nip area. Weighted rod 80 descends slowly to maintain the biasing of web 72 to roller 49. The web member motion stops at that point and the copy sheet is moved along by fuser roll 49 rotation. The sheet progresses through the contact (fusing) area until it emerges from exit area 104. When the trailing edge clears exit area 104, controller 95 energizes motor 98 in a reverse drive causing drive roller 74 to rotate in a clockwise direction returning web member 72 to its original position.
FIG. 3 shows a second embodiment of the invention where the web member 72 is reciprocated between a take-up roller 110 and a feed roller 112. One end of the web is wound around take-up roller 110; the web rides over curved portion of web frame 88. The web biasing force is again supplied by a blade member 90. The other end of web member 72 is wound around feed roller 112. The copy sheet is maintained in a flat condition as it approaches the nip area by conveying the sheet along the top perforated surface 114 of vacuum chamber 116. The copy sheet rides on web member 72 which is porous enough to permit a vacuum force to engage and hold the copy sheet flat. The copy sheet is engaged at the time it leaves detack area 28.
For this embodiment, system controller 95 is programmed to provide signals causing roller 110 to rotate in a counterclockwise direction by means of a drive motor 99. As the leading edge of copy sheet 32 leaves the detack area 28, web 72 is moved so as to move at the same speed as the copy sheet as it leaves the detack area. The web motion is stopped when the leading edge of the copy sheet is past the nip area, but the rest of the sheet maintains its flat orientation along the vacuum surface until the entire sheet passes through the nip entrance 93. When the trailing edge of the sheet emerges from exit area 104, the system controller sends a reverse drive signal to drive motor 99 reversing rotation of take up roller 112, and causing web member 72 to rewind to its original position.
While the invention has been described with reference to the structure disclosed, it will be appreciated that numerous changes and modifications are likely to occur to those skilled in the art, and it is intended to cover all changes and modifications which fall within the true spirit and scope of the invention. | A low mass fuser roll fusing system incorporates a thin web member to maintain copy sheets in biased contact with a fuser roll during a fusing operation. The copy sheets are introduced to the fusing area at an entrance nip formed by a biasing assembly. The lead edge of the copy sheet is introduced into the entrance nip by a reciprocating mecahnism which moves, the web member and the copy sheet supported thereon into the entrance nip. The web member motion is then stopped and the copy sheet progresses through the fusing cycle until the copy sheet emerges from the fusing area, at which time the web member is returned to its original position. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is directed to roof construction and suspended ceiling system and, more particularly, to a fire rated suspended ceiling system.
2. Description of the Prior Art
This invention concerns a roof structure and suspended ceiling system consisting of a roof with a watertight outer layer and a layer of thermal insulation beneath it, resting on a metal roof-supporting surface that has a vapor barrier, plus a suspended ceiling that is suspended from the roof-supporting surface with the ceiling tile supported by suspended rails.
There is already a known roof structure and suspended ceiling system in which the rails that support the ceiling tiles of the suspended ceiling are suspended from a metal corrugated roof-supporting surface. The roof-supporting surface has a layer of sheet gypsum on its upper side and a layer of thermal insulation such as mineral wool above it, and this is sealed by a watertight outer layer. The roof-supporting surface forms a vapor barrier (German Patent Application No. 2,705,032). It is also known that a layer of asphalt can be applied to the roof-supporting surface to form the vapor barrier.
It has been found that in the event of fire, the fire resistance of this system does not meet the 90-minute requirement, despite the layer of sheet gypsum on the roof-supporting surface that forms a heat sink, because the metal roof-supporting surface reaches excessively high temperatures too rapidly.
To prevent this rapid heating of the metal roof-supporting surface in the space beneath the suspended ceiling in the event of fire, a layer of mineral wool could be appplied as thermal insulation to the ceiling tiles of the suspended ceiling, but the disadvantage of this arrangement is that in unfavorable weather conditions, the dew point in the space between the suspended ceiling and the roof-supporting surface could shift, so the suspended ceiling would be exposed to moisture, and this must be avoided at all costs.
To keep the dew point outside the space, even in very cold weather, the layer of thermal insulation on the roof-supporting surface would have to be increased considerably, so that increased cost due to this method would result in a very expensive roof structure and suspended ceiling system.
SUMMARY OF THE INVENTION
The invention is directed to a roof construction and subceiling assembly consisting of a water impermeable outer layer and a heat insulating layer installed below the outer layer, both of which rest on a metal deck which is a vapor barier. Below the metal deck, a subceiling is suspended with ceiling boards supported by suspended supporting runners. A heat insulating layer is installed between the deck and the subceiling. At points of the subceiling determined by ventilation aspects of the ceiling boards, the overlying intermediate insulation material and ceiling boards are lifted to form an air passage between the area below the suspended ceiling and the area between the subceiling and the deck. Ceiling boards are also maintained at these points in a lifted position by a member which will meet, decompose, or otherwise lose its consistency under the influence of heat and that after the decomposition of said member, said ceiling boards together with the overlying insulation layer, will fall into position substantially closing the subceiling and form a fire barrier between the area below the subceiling and the area above the subceiling.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows one version of a roof structure and suspended ceiling system in sectional view;
FIG. 2 shows a sectional view of a raised ceiling tile; and
FIG. 3 shows the arrangement in FIG. 2 again in prospective.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention herein is based on the task of designing a roof structure and suspended ceiling system of the type described initially in such a way that with a relatively minor addition of expense in terms of material, fire resistance can be achieved that corresponds at least to the 90-minute limit.
Starting with the roof structure and suspended ceiling system of the type described initially, the problem of fire resistance is solved by adding an intermediate layer of thermal insulation in the space between the roof-supporting surface and the suspended ceiling in such a way that the ceiling tiles and the intermediate insulation material above it are elevated at certain points (determined on the basis of ventilation considerations) to form air passages between the spaces above and below the suspended ceiling. These ceiling tiles are held in raised position by at least one element of a substance that melts, dissolves, or otherwise loses its strength under the influence of heat, in such a way that in the absence of this element, the ceiling tiles and the intermediate insulation material above them will drop into a position sealing the suspended ceiling and intermediate layer, where they are held by means of the supporting rails.
The roof structure and suspended ceiling arrangement, according to this invention, has the advantage that despite the intermediate layer of thermal insulation material, the space between the roof-supported surface and the suspended ceiling is sufficiently ventilated so that there cannot be a shift in the dew point in this space. In the event of a fire in the space beneath the suspended ceiling, the element supporting the upward tilted ceiling tiles dissolves, or otherwise loses it strength very rapidly owing to the heat evolved, so the supporting effect is lost and both the ceiling tiles and intermediate insulation on it drop down under the influence of gravity, so they completely cover the ceiling area previously exposed when they were tilted upward, i.e., completely sealing the passage of air in the space between the roof-supporting surface and the suspended ceiling, while at the same time, the intermediate layer of thermal insulation material forms a continuous layer in this space. At this moment, a shift in dew point is no longer of interest. Due to the insulating effect of this suspended ceiling and the intermediate layer above it, the roof-supporting surface will heat only gradually, so the roof structure and suspended ceiling system has a fire resistance that lasts to 90 minutes or more, i.e., it achieves the fire resistance of concrete systems.
A device is already known for sealing an opening in a fireproof ceiling with a solid member that surrounds it in the form of a frame and at least one fireproof sheet to cover the opening, with an element that holds the sheet directly in the open position inserted between the fireproof sheet and a solid member of the fireproof ceiling, such that said element consists of a substance that melts, dissolves, or otherwise loses its strength under the influence of heat (for example polystyrene foam is suitable for this purpose, German Pat. No. 1,658,786). The surprising advantageous use of such a device according to this invention for solving the dew point problem while at the same time achieving a higher fire resistance class for a roof structure and suspended ceiling system cannot, however, be deduced from this state of the art.
It is advantageous for the ceiling tiles with the intermediate insulation material above them to be held in an upward inclined position on a supporting rail and to be held in this position by at least one element consisting of a material that melts, dissolves, or otherwise loses its strength under the influence of heat and is positioned on the supporting rails. The air passage thus achieved at the predetermined locations is great enough to ventilate the space between the roof-supporting surface and the suspended ceiling adequately. In the event of a fire, the raised ceiling tiles drop into the closing position when their supporting element dissolves, completely sealing the suspended ceiling and not preventing any flow of air into the space between the roof-supporting surface and the suspended ceiling. At the same time, the intermediate layer of insulation material above the ceiling tile is tilted in the direction of the suspended ceiling, forming an essentially continuous intermediate layer of thermal insulation.
It is advantageous for the tilted ceiling tiles to be in guide rails that hold the position closing the suspended ceiling and secure the tiles in a continuous suspended ceiling and continuous intermediate layer in the event of a fire. This can be accomplished by means of guide plates, wire clips, etc. An ornamental grill or a light transmitting grill that allows air to pass through can be placed at those locations where the ceiling tiles are raised so the visual impression of this suspended ceiling will not be impaired by the raised ceiling tiles. When the supporting element melts in the event of a fire, the ceiling tile drops down onto the relatively thin grill, or if the grill itself dissolves due to heat, the ceiling tile will drop down onto the supporting rail, so again, a continuous suspended ceiling is formed, preventing the passage of air into the space between the roof-supporting surface and the suspended ceiling, and maintaining a continuous intermediate layer of thermal insulation.
As mentioned above, the element that melts under the influence of heat should consist of a foam plastic such as polystyrene foam that melts at 70° C. to 80° C.
The roof structure and suspended ceiling system shown in the figures consist of a roof-supporting surface of sheet metal with corrugated reinforcements. A vapor barrier may be provided by the roof-supporting surface itself or it may consist of a layer of asphalt or aluminum foil applied to the roof-supporting surface 4. Above layer 3, there is a layer of thermal insulation 2 which may consist of mineral wool, for example. This layer of thermal insulation 3 is sealed on the outside by a water-tight layer 1 which may consist of film or roofing paper.
The ends of T-shaped supporting rails 8 are suspended from the roof-supporting surface 4 with the help of wires 5, the flanges 10 support the ceiling tiles 7 of a suspended ceiling system. Such a suspended ceiling system is also referred to as a strip grid ceiling. An intermediate layer 11 of thermal insulation is applied to the ends 9 of supporting rails 8 and this layer may consist of mineral wool.
At certain locations, a thin grill 15 is laid on the flange 10 of adjacent supporting rails 8. In the area of one supporting rail 8, one edge of a ceiling tile 13 lies on this grill 15, with the tile tilted upward and supported by means of wedge-shaped element 14 that rests on the grill 15 in the area of the adjacent supporting rail 8. Together with the ceiling tile 13, the intermediate layer 16 of insulating material above the ceiling tile is also tilted upward, and for this reason, the intermediate layer 11 is cut along the plane of separation 12.
Owing to the fact that the ceiling tiles 13 are tilted upward, air can flow from space 21 into space 20 and vice versa through the air passage 22 and the grill 15, so that air circulation in space 21 influences space 20 in such a way that despite the intermediate layer 11 of thermal insulation, there cannot be a shift of dew point into the interior of space 20, even under extremely unfavorable weather conditions.
The elements 14 that are in the form of a cube in FIGS. 2 and 3, and in the form of a wedge in FIG. 1 consist of a material such as polystyrene foam that melts and dissolves very rapidly under the influence of heat. In the event of a fire in space 21, ceiling tile 13 therefore drops into a horizontal position on the grill 15 when element 14 loses its strength due to heat, or if the grill is made of the same material as element 14 that dissolves under heat and the ceiling tile drops onto the supporting flange of the adjacent supporting rails 8, closing the air passage 22. At the same time, the intermediate layer 16 of insulation material on the ceiling tile 13 also drops into horizontal position, forming a continuous intermediate layer 11. Air is also prevented from passing between spaces 20 and 21. In addition, good thermal insulation of space 20 against space 21 is also achieved, so the roof-supporting surface 4 can heat only very slowly, and roof structure and suspended ceiling system as a whole has a fire resistance according to the 90-minute limitation and even considerably better.
As shown in FIGS. 2 and 3, the ceiling tiles 13 with the intermediate layer 14 of insulation material above them can be raised into vertical position to form the air passage 22 and kept in this position by cubicle elements 14. When these elements 14 dissolve under the influence of heat in the event of a fire in space 21, the ceiling tiles 13 with the intermediate layer 16 of insulation material will drop into the proper closing position in the U-shaped guides 23 at the side under the influence of gravity. | A roof construction-suspended ceiling system consists of a watertight outer layer and a layer of thermal insulation beneath it resting on a metal roof-supporting surface that has a vapor barrier. Below this there is a suspended ceiling system that has insulation placed thereon. The suspended ceiling has openings that will vent the area between the roof construction and the suspended ceiling and the above-said openings may be quickly closed in the event of a fire below the suspended ceiling system. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates generally to guards for rain gutters on buildings, and more particularly, is directed to a gutter guard having two drainage sections and a heating mechanism associated therewith.
It is well-known to provide guards on top of gutters to prevent leaves from falling into the gutters, while permitting water to drain into the gutters. Examples of known arrangements presently being sold are, for example, the system sold under the registered trademark “GUTTER TOPPER” by Gutter Topper Ltd., L.L.C. Of Amelia, Ohio; the system sold under the registered trademark “GUTTER CAP” by Selective Seamless Siding Co. of Naperville, Ill.; and the system sold under the registered trademark “LEAFPROOF” by Eran Industries, Inc. of Omaha, Nebr.
In these systems, the gutter guard includes a sheet of metal that covers the gutter, and has a curved forward end that extends back into the gutter. Thus, leaves and the like are prevented from entering the gutter, but because of surface tension, water flows along the forward curvature of the guard and falls through small openings thereat into the gutter, where the water is carried away to the down spout.
One problem with these systems is that during a heavy water flow, because of the large volume of water, much of the rain water will tend to fall off the roof from the curved end of the gutter guard, rather than flow around the curved end into the gutter. In such case, the gutter guard, although preventing leaves and the like from entering the gutter, does not provide the function of guiding the rain water into the gutter.
In an attempt to solve this problem, U.S. Pat. No. 4,404,775 to Demartini discloses a gutter guard in which there are bumps to slow down the velocity of the rain water so that it travels around the bend into the gutter. U.S. Pat. No. 5,557,891 to Albracht discloses a gutter guard having water slowing means in the form of an S-shaped bend spaced rearwardly of the forward curved portion.
However, the problem with these approaches is that, during heavy rain, there is still too much rain water, so that much of the rain water will still fall off the roof from the curved end of the gutter guard, and will not travel by surface tension around the curved front end, into the gutter.
Another problem with such gutter guards is that ice and snow tend to accumulate thereon, which impedes the flow of water, and or, defeats the surface tension aspect so that the water falls from the roof at the curved end of the gutter guard.
Various proposals have been presented for adding heating elements to gutter guards in order to avoid this problem. For example, U.S. Pat. No. 4,308,696 to Schroeder discloses a gutter guard having heating elements as lengthwise extending strips on the flat upper surface portion of the gutter guard. U.S. Pat. No. 4,769,526 to Taouil discloses bent, raised portions extending along the length thereof, with heating cables positioned to the lower surface of the bent, raised portions. The heating cables are positioned between the roof and the gutter guard. In order to retain the heating cables in place during assembly, a dielectric adhesive-tape secures the cables in the bent, raised portions. U.S. Pat. No. 5,786,563 to Tiburzi discloses modular ice and snow removal heating panels for a gutter guard system having a built-in flexible heating layer.
However, none of these proposals are entirely satisfactory in that they are complex and burdensome to assemble, and are costly.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a gutter guard that overcomes the problems with the aforementioned prior art.
It is another object of the present invention to provide a gutter guard having two spaced apart drainage sections, both of which drain separately into the gutter.
It is still another object of the present invention to provide a gutter guard in which the first drainage section removes water during a heavy rain so that the remaining water travels around the curved free end by surface tension into the gutter through the second drainage section.
It is a yet another object of the present invention to provide a gutter guard in which the first and second drainage sections have similar shapes and functions.
It is a further object of the present invention to provide a gutter guard having a heating wire mounted in the upstream first drainage section for heating the gutter guard to melt any snow or ice thereon.
It is a still further object of the present invention to provide a gutter guard in which the S-shape of the upstream first drainage section holds, secures and protects the heating wire.
In accordance with an aspect of the present invention, a gutter guard includes a first inclined section of water impervious material having a rear end adapted for insertion below shingles of a roof of a building; a second inclined section of water impervious material; and a securing section for securing a front end of the gutter guard to a gutter of the building. A first drainage section connects a front end of the first inclined section to a rear end of the second inclined section. When the rear end of the first inclined section is inserted below the shingles and the securing section is secured to the gutter, the first drainage section is positioned above an open end of the gutter for draining water thereinto. A second drainage section connects a front end of the second inclined section with the securing section. When the rear end of the first inclined section is inserted below the shingles and the securing section is secured to the gutter, the second drainage section is positioned above the open end of the gutter for draining water thereinto.
The first or second drainage sections, and preferably both, include a forwardly facing convex surface around which water travels; and at least one opening at a position below the forwardly facing convex surface through which water traveling around the forwardly facing convex surface exits into the gutter.
Specifically, the first drainage section includes an S-shaped bend including an upper forwardly facing convex surface over which water travels and a lower forwardly facing concave surface having the at least one opening therein. The upper forwardly facing convex surface has an upper edge connected with a front edge of the first inclined section, and the lower forwardly facing concave surface has a lower edge connected with a rear edge of the second inclined surface. Preferably, there are a plurality of openings in the lower forwardly facing concave surface that extend to a height which is at least equal to one-half the height of the lower forwardly facing concave surface, and more preferably, the openings also extend at least partially in the upper forwardly facing convex surface.
The second drainage section includes a channel below the forwardly facing convex surface thereof, and the at least one opening is provided in at least one wall of the channel. Preferably, there are a plurality of the openings in the at least one wall of the channel. More preferably, the channel is a U-shaped channel and the openings are provided in adjacent bottom and side walls of the channel. The securing section is connected with a front portion of the channel of the second drainage section.
The securing section includes an inverted U-shaped channel adapted to fit over a front upper edge of a gutter.
There is further a heating device positioned in the first drainage section for heating the gutter guard to melt any snow and ice thereon. The heating device includes a heating wire, and the heating wire is positioned at the lower forwardly facing concave surface. In one embodiment, the heating wire is fixed to the lower forwardly facing concave surface.
The above and other objects, features and advantages of the invention will become readily apparent from the following detailed description thereof which is to be read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a gutter guard according to the present invention;
FIG. 2 is an enlarged perspective view of a portion of the gutter guard;
FIG. 3 is a cross-sectional view of the gutter guard in its installed condition; and
FIG. 4 is an elevational view of the gutter guard, viewed along line 4 — 4 of the FIG. 1 .
DETAILED DESCRIPTION
Referring to the drawings in detail, and initially to FIGS. 1–4 thereof, a gutter guard 10 according to the present invention includes an elongated thin metal sheet 12 bent in a particular manner for fitting over a gutter 14 to prevent leaves and other debris from entering gutter 14 , while still permitting water to enter gutter 14 . It will be appreciated that the side to side length of gutter guard 10 is preferably made of a generally very long section, for example, five feet long, and is merely shown in a reduced length scale for purposes of illustration herein. Further, in the general concept of the present invention, a material other than metal can be used, such as plastic or other water impervious material. Preferably, as will be appreciated from the discussion hereafter, the material is a heat conducting material.
Specifically, metal sheet 12 includes an upper inclined, substantially planar section 16 of a generally rectangular shape, having an inclination relative to the horizontal of about 15°–25°. The upper free edge 18 of upper inclined section 16 is intended to be slipped under shingles 20 or shakes on a roof 22 of a building, so that any rain water which falls from roof 22 continues falling on the upper surface of upper inclined section 16 . Upper inclined section 16 extends at the same pitch as roof 22 , and extends outwardly from roof 22 to a position above gutter 14 . Upper inclined section 16 can also be formed with various small bends, such as the triangular shaped bend 24 or stepped bend 26 shown in FIG. 1 . Bends 24 and 26 function as stiffening ribs. Triangular shaped bend 24 may also aid in slowing down the flow rate of any rain water.
An S-shaped bend 28 forming a first drainage section extends down from the lower edge 30 of upper planar section 16 such that the upper edge 32 of S-shaped bend 28 is integrally secured as one-piece with the lower edge 30 of upper planar section 16 . S-shaped bend 28 thereby includes an upper forwardly facing convex surface 34 over which water travels and a lower forwardly facing concave surface 36 . Concave surface 36 includes a plurality of openings 38 extending therealong. Although the openings are shown in an oval or oblong shape, the present invention is not limited thereby. Openings 38 also extend upwardly so that openings 38 preferably extend at least partially in upper convex surface 34 . With such an arrangement, some of the water traveling from upper inclined section 16 to S-shaped bend 28 , travels around upper convex surface 34 by means of surface tension and then travels through openings 38 into gutter 14 . This reduces the amount of rain water traveling to the next section.
Metal sheet 12 further includes a lower inclined, substantially planar section 40 of a generally rectangular shape, having the same inclination relative to the horizontal of about 15°–25°. The upper edge 42 of lower planar section 40 is connected with the lower edge 44 of lower forwardly facing concave surface 36 of S-shaped bend 28 . As a result of S-shaped bend 28 , it will be appreciated that lower inclined planar section 40 is parallel with, but spaced lower than, upper inclined planar section 16 .
A bullnose section 46 extends down from the lower edge 48 of lower inclined planar section 40 such that the upper edge 50 of bullnose section 46 is integrally secured as one-piece with the lower edge 48 of lower inclined planar section 40 . Bullnose section 46 thereby includes a forwardly facing convex surface 52 over which water travels. With such an arrangement, the remaining-water traveling from lower inclined section 40 to bullnose section 46 , travels around forwardly facing convex surface 52 by means of surface tension.
Metal sheet 12 further includes a U-shaped channel section 54 integrally formed at the lower edge 56 of bullnose section 46 . Specifically, U-shaped channel section 54 includes a rear vertically oriented wall 58 having an upper edge 60 integrally secured as one-piece with the lower edge 56 of bullnose section 46 , a lower horizontally oriented wall 62 having a rearward edge 64 secured as one-piece with the lower edge 66 of rear vertically oriented wall 58 , and a front vertically oriented wall 68 having a lower edge 70 secured as one-piece with the forward edge 72 of lower horizontally oriented wall 62 .
A plurality of openings 74 are formed at the connection between rear vertically oriented wall 58 and lower horizontally oriented wall 62 . Openings 74 extend approximately to one-half the height of rear vertically oriented wall 58 and one-half the width of lower horizontally oriented wall 62 . Although openings 74 are shown in an oval or oblong shape, the present invention is not limited thereby. With such an arrangement, the remaining water traveling from lower inclined section 40 to bullnose section 46 , travels around forwardly facing convex surface 52 by means of surface tension and then travels through openings 74 into gutter 14 .
Bullnose section 46 and U-shaped channel section 54 together from a second drainage section.
Metal sheet 12 further includes an inverted U-shaped channel section 76 integrally connected as one-piece at the upper edge 78 of front vertically oriented wall 68 , in order to secure the forward end of gutter guard 10 to the upper bent front end 79 of gutter 14 , as shown in FIG. 3 . Specifically, inverted U-shaped channel section 76 is formed by front vertically oriented wall 68 , an upper horizontally oriented wall 80 having a rearward edge 82 secured as one-piece with the upper edge 78 of front vertically oriented wall 68 , and a frontmost vertically oriented wall 86 having an upper edge 88 secured as one-piece with the forward edge 90 of upper horizontally oriented wall 80 .
As shown in FIG. 3 , the upper edge 79 of gutter 14 includes an inward L-shaped bent section formed from an upwardly extending wall 92 and a rearwardly extending horizontal wall 94 having its front edge secured to the upper edge of upwardly extending wall 92 . Inverted U-shaped channel section 76 is preferably friction fit over the L-shaped bent section such that rearwardly extending horizontal wall 94 fits snugly between front vertically oriented wall 68 and frontmost vertically oriented wall 86 , and is positioned immediately below upper horizontally oriented wall 80 . In this manner, the rear end of gutter guard 10 is secured under roof shingles 20 and the front end of gutter guard 10 is secured to L-shaped bent section 90 of gutter 14 . If desired, although not required, in order to provide a greater securement to gutter 14 , nails, screws or the like 96 can secure upper horizontally oriented wall 80 to rearwardly extending horizontal wall 94 .
With the arrangement thus far described, the rain falling from roof shingles 20 will fall along the upper surface of upper inclined section 16 to S-shaped bend 28 . Some of the rain will travel around upper convex surface 34 by means of surface tension and then travel through openings 38 into gutter 14 . This reduces the amount of rain water traveling to the next section. The remaining water will travel around forwardly facing convex surface 52 by means of surface tension and then travel through openings 74 into gutter 14 . In this manner, during heavy downpours, S-shaped bend 28 and the openings 38 therein will reduce the amount of rain traveling around bullnose section 46 . This will substantially reduce the possibility of rain falling off the roof from bullnose section 46 .
In accordance with another aspect of the present invention, an insulated heating wire 98 is positioned in lower forwardly facing concave surface 36 of S-shaped bend 28 , and secured thereto by adhesive 100 or the like. Alternatively, adhesive 100 can be eliminated, and heating wire 98 can be merely positioned in lower forwardly facing concave surface 36 of S-shaped bend 28 .
Heating wire 98 heats the metal of metal sheet 12 of gutter guard 10 by being in contact therewith. As a result, any snow or ice that forms on gutter guard 10 is melted and does not impede the flow of water to gutter 14 . Because of the S-shaped bend 28 , heating wire 98 fits within lower forwardly facing concave surface 36 of S-shaped bend 28 . This differs from conventional heating wires that are merely positioned on the upper exposed surface of the gutter guards where they are more readily exposed to the elements and can more easily become dislodged, and from heating wires that are formed at the lower surface of the gutter guards, which are more complicated and burdensome to assemble. With this arrangement of the present invention, heating wire 98 is less prone to escape from lower forwardly facing concave surface 36 , and at the same time, is protected at least partially from the elements.
It will further be appreciated that, because openings 38 extend upwardly to an extent preferably at least partially in upper convex surface 34 , the upper ends of openings 38 are at a height which is above heating wire 98 . As a result, water traveling around upper forwardly facing convex surface 34 , will fall through openings 38 before substantially hitting heating wire 98 . The remaining water will fall like a waterfall onto lower planar section 40 without substantially impinging upon heating wire 98 .
Having described a specific preferred embodiment of the invention with reference to the accompanying drawings, it will be appreciated that the present invention is not limited to that precise embodiment and that various changes and modifications can be effected therein by one of ordinary skill in the art without departing from the scope or spirit of the invention defined by the appended claims. | A gutter guard includes a first inclined section for insertion below shingles of a roof; a second inclined section; and a securing section securing a front end of the gutter guard to a gutter of the roof. A first S-shaped drainage section connects the first inclined section to the second inclined section, and is positioned above an open end of the gutter for draining water thereinto. A second drainage section connects the second inclined section with the securing section, and is positioned above the open end of the gutter for draining water thereinto. The drainage sections each include a forwardly facing convex surface around which water travels, and openings at positions below the convex surfaces through which water exits into the gutter. A heating wire is positioned in the S-shaped drainage section. | 4 |
[0001] This application claims the benefit of U.S. provisional patent application Ser. No. 60/219,520 filed Jul. 20, 2000.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to a device for lifting a mower deck suspended from a riding mower, and more specifically, to a foot actuated deck lift mechanism for lifting a mower deck automatically from a cutting position to a transport position.
DESCRIPTION OF THE RELATED ART
[0003] There are a number of known devices for lifting a mower deck on a riding mower to a transport position. These devices typically include a hand actuated lift lever. U.S. Pat. No. 5,816,033 to Busboom et al. discloses a riding mower having an improved mower deck height control mechanism including an elongated deck height control lever pivotally movable from a lower position with respect to the frame means, to an upper position wherein, the mower deck is in its uppermost transit position. These types of deck lift arrangements require an operator to remove a hand from the drive controls or stop the mower to raise the deck to the transport position. Additionally, hand adjustment lift levers can require considerable force to raise a mower deck, particularly larger decks.
[0004] In U.S. Pat. No. 5,138,825 to Trefz et al., a pedal operating lifting system is provided for replacing conventional hand operating levers. The pedal also includes a locking mechanism located on the pedal mechanism for locking the deck in the uppermost position. In U.S. Pat. No. 5,351,467 to Trefz et al, a pedal operating lifting system is provided with unlimited adjustability within a range established by the maximum and minimum deck mower heights. The '825 and '467 patents disclose a pedal operated deck lifting system but do not include the advantages of the system disclosed by the present invention.
[0005] Accordingly, there is a need in the art for a mower deck lift mechanism that may be operated without the sole use of an operator's hands. Furthermore, there is a need for a mower deck lift assembly that may be easily attachable as an after market device addition to a riding mower, as well as a standard feature on a stock mower.
SUMMARY OF THE INVENTION
[0006] This invention provides a foot actuated mower deck lift device to lift a mower deck from a cutting position to a transport position without the sole use of the operator's hands.
[0007] More specifically, the invention is directed towards a lift mechanism that is hand and/or foot actuated for lifting a deck attached to a mower, and particularly, a mower deck attached to a riding lawn mower.
[0008] The present invention discloses a system that includes the cooperation of a lift handle with a foot pedal increasing mechanical system leverage and reducing the force required by the operator to engage the system. The present invention also can be operated solely by a foot pedal and without the use of the operator's hands. Finally, the present invention includes a locking transport position positively engaged by a lift pin incorporated into the lift lever.
[0009] According to the invention, the deck lift mechanism comprises a frame, a lift lever, inner and outer height adjustment plates, lift linkages, a front lift shaft, a rear lift shaft, shaft connecting linkages, and a pedal lever.
[0010] In accordance with an embodiment of the invention, the lift lever is pivotally coupled to a frame and has a pin movably attached thereto. A lift linkage has a first end pivotally coupled to the lift lever and a second end fixedly secured on a front shaft. A connecting linkage pivotally couples the front shaft to a rear shaft. Both the front and rear shafts are rotatably coupled to the frame. The pedal lever has a first end fixedly secured to the front shaft and a second free end for operation with the operator's foot.
[0011] In accordance with an aspect of this invention, it is desirable to provide a cutting system that permits the operator to change the cutting height while seated using an adjustment pin.
[0012] In accordance with another aspect of this invention, it is further desirable to provide a cutting system wherein the operator can raise the mover deck without the use of the operator's hands to a transport position and return the deck to that exact cutting position once the transport is completed.
[0013] In accordance with another aspect of this invention, it is further desirable for the lift assembly to be easily attachable as an after market device, in addition to being a standard stock feature.
[0014] These and other aspects of this invention are illustrated in the accompanying drawings, and are more fully disclosed in the following specification.
DETAILED DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is an elevation view of a riding mower incorporating the deck lift mechanism in a lowered cutting position;
[0016] [0016]FIG. 2 is an elevation view of a riding mower incorporating the deck lift mechanism in a transport position;
[0017] [0017]FIG. 3 is an isolated exploded view of the deck lift mechanism;
[0018] [0018]FIG. 4 is a perspective view of a pedal lever connected to a pedal and a deck lift lever;
[0019] [0019]FIG. 5 is a front view of the pedal lever and pedal;
[0020] [0020]FIG. 6 is a side view of the pedal lever of FIG. 5; and
[0021] [0021]FIG. 7 is a side view of a tightening plate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] [0022]FIGS. 1 and 2 illustrate a foot actuated deck lift mechanism 10 according to the present invention. The deck lift mechanism 10 is shown in its intended operating position, attached to a riding mower, for lifting a mower deck 12 from a cutting position to a transport position. While the remaining components of a riding lawn mower are not shown in the appended drawings, it is expected that those skilled in the art will be intimately familiar with the omitted components, all which are generally conventional.
[0023] Referring now to FIG. 1, the deck lift mechanism 10 is shown in a lowered cutting position. FIG. 2 illustrates the deck lift mechanism 10 in a raised transport position. Provided in the deck lift mechanism 10 are a pair of height adjustment plates 16 , 18 for securing the deck 12 in the transport position and for positioning the deck at a plurality of particular vertical cutting positions 58 .
[0024] As shown in FIG. 3, the deck lift mechanism 10 includes a lift lever 14 , inner and outer height adjustment plates 16 , 18 , lift linkages 20 , a front lift shaft 22 , a rear lift shaft 24 , shaft connecting linkages 26 , and a pedal lever 28 .
[0025] Preferably, the deck lift mechanism 10 is actuated solely by an operator's foot using pedal lever 28 to raise the mower deck 12 to a transport position. Alternatively, the deck lift mechanism 10 may be raised to the transport position by the use of an operator's hand using lift lever 14 , or by the use of an operator's foot using pedal lever 28 assisting the hand using lift lever 14 .
[0026] The lift lever 14 is carried on the frame 29 of the vehicle and has an upper end positioned for engagement with the operator's right hand and a lower end pivotally coupled with the frame 29 . The lower end provides a peg member 30 formed integral with the lift lever 14 . The peg member 30 is pivotally received by an opening formed in the vehicle frame 29 . The peg 30 defines the axis about which the lift lever 14 pivots. The upper end angles into the operator's control area 32 to provide a handle for placement of the operator's hand.
[0027] As shown in FIG. 3, and illustrated by hidden lines in FIGS. 1 and 2, a spring assembly 34 is attached to the lift lever 14 between the upper and lower ends. The spring assembly 34 includes a pair of guides 36 , 38 , a spring 40 and a lift pin 42 . The upper guide 36 is generally shaped as an inverted L with a body portion and a top portion. The body portion of the upper guide 36 , is fixedly secured to the lift lever 14 by nut and bolt assemblies 44 . The lower guide 38 is welded to the lift lever at the bottom of the upper guide 36 . The spring 40 preferably is a compression spring and is axially positioned between, and restricted by, the guides 36 , 38 . The lift pin 42 is generally shaped as an inverted L. The upper end of the lift pin 42 is spaced at a distance from the lift lever handle 33 such that the operator's fingers can grasp the lift pin 42 while maintaining their palm on top of the handle 33 . The lower end of the lift pin 42 slidably extends through coaxially aligned openings 46 , 48 formed in the top portion of the upper guide 46 and in the lower guide 48 , and through the inside diameter of the spring 40 . A pin 50 is received in an aperature 51 in the lift pin 42 between the lower guide 38 and the bottom of the spring 40 . The pin 50 is longer than the outside diameter of the spring 40 and, therefore, carries the spring 40 upwards when the lift pin 42 is lifted upwards thereby compressing the spring 40 between the pin 50 and the top portion of the upper guide 36 .
[0028] As shown in FIG. 3, the preferred embodiment also provides a pair of height adjustment plates 16 , 18 for securing the deck 12 in a transport position and for positioning the deck at a plurality of particular vertical cutting positions. The inner adjustment plate 16 is welded to the frame 29 . The outer adjustment plate 18 is fixedly attached to the inner adjustment plate 16 by front and rear nut, spacer and bolt assemblies 52 , 53 . The spacers 54 maintain the adjustment plates 16 , 18 a fixed distance apart to provide a channel 56 between the adjustment plates 16 , 18 . Both adjustment plates 16 , 18 , have two rows of radially spaced apart height adjustment openings 58 at fixed intervals which provide the variety of cutting positions. The openings 58 in the adjustment plates 16 , 18 coaxially align and are positioned between the front and rear nut, spacer and bolt assemblies 52 , 53 . The forward most opening 60 provides the lowest cutting position and each subsequent opening incrementally increases the cutting height.
[0029] Referring again to FIG. 3, the lift lever 14 extends through the channel 56 formed by the adjustment plates 16 , 18 with the peg member 30 below, and the handle 33 above the adjustment plates 16 , 18 . The lift lever 14 radially moves along the channel 56 and is configured between the front and rear nut, spacer and bolt assemblies 52 , 53 .
[0030] As shown in FIGS. 1 and 2, the outer adjustment plate 18 is provided with an arcuate top rail 62 , uniformly distant from the peg member 30 upon which the bottom end of the lift pin 42 slides. A transport opening 64 for setting the deck into the transport position is formed by a contiguous recess, which extends through the top rail 62 into the outer adjustment plate 18 . The transport opening 64 is located rearward of the height adjustment openings 58 .
[0031] The lift pin 42 is biased against the top rail 62 by the spring 40 . When the lift pin 42 is positioned over the transport opening 64 , the spring 40 urges the lift pin 42 into the transport opening 64 thereby securing the deck 12 into the transport position. Preferably, the deck 12 is raised to a six-inch cutting height when in the transport position.
[0032] A height adjustment pin 66 , shown in FIG. 3, provides intermediate positioning of the deck 12 . The deck height is selected by inserting the height adjustment pin 66 through a coaxially aligned pair of height adjustment openings 58 to form a crossbeam through the channel. The lift lever 14 contacts and rests upon the height adjustment pin 66 under the force of gravity when setting the cutting height. For storage purposes and so that it does not get misplaced, the height adjustment pin 66 is attached to the outer height adjustment plate 18 by a wire, rope or chain.
[0033] A pair of laterally spaced lift linkages 20 include first ends pivotally coupled with the lift lever 14 , and second ends pivotally coupled with integral connection lever 68 fixedly provided on the front lift shaft 22 .
[0034] The front and rear lift shafts 22 , 24 are rotatably coupled to the frame 29 in any known manner. The lift shafts 22 , 24 are each provided with integral connection levers 70 . A pair of connecting linkages 26 are pivotally secured to the levers 70 on the front lift shaft 22 and the rear lift shaft 24 to form a parallel linkage, thereby pivotally coupling the front lift shaft 22 to the rear lift shaft 24 , such that rotation of the front lift shaft 22 is equally transmitted to the rear lift shaft 24 .
[0035] A pair of deck lift levers 72 are integrally provided on the front and rear lift shafts 22 , 24 . An opening 74 is provided in an outer end of each of the deck lift levers 72 . Chains 76 having an upper end attached to the openings 74 and a lower end attached to the deck 12 , support the weight of the deck 12 .
[0036] Springs 78 , preferably of the tension type, include a first end attached to the levers 70 on the rear lift shaft 24 and a second end attached to the frame 29 . The springs bias the rear lift shaft 24 towards the direction of rotation in which the deck 12 is lifted. The aggregate force of the springs 78 offsets a portion of the weight of the deck 12 to assist the operator when raising the deck 12 . Additional levers and springs can be provided to increase the biasing force.
[0037] As shown in FIGS. 4 and 5, the pedal lever 28 has a lower portion 80 , a middle portion 82 and an upper portion 84 . The middle portion 82 preferably angles towards the control area 32 from the lower portion 80 by forty-five degrees and the upper portion 84 preferably angles toward the control area 32 from the middle portion 82 by forty-five degrees for ergonomic operation by the operator's right foot.
[0038] The lower portion 80 is removably secured to the right front deck lift lever 72 . Particularly, a tightening plate 86 cooperates with the lower portion 80 to sandwich an intermediate section of the pedal lever 28 therebetween. Preferably, two groups of three openings 88 , 90 are provided, one group 88 in the tightening plate 86 and the other group 90 in the deck lift lever 72 as illustrated in FIGS. 4, 6 and 7 . The groups of openings 88 , 90 coaxially align for receiving nut and bolt assemblies. Two sets of the coaxially aligned openings are positioned above, and one set of the openings below, the deck lift lever 72 . Each group of the openings 88 , 90 are orientated as vertexes of an obtuse triangle. Each nut and bolt assembly is disposed adjacent the circumferential edge of the deck lift lever 72 , and preferably is connected thereto.
[0039] As shown in FIGS. 4 and 5, a pedal 92 is fixedly secured to an inward facing edge of the upper portion 84 . The pedal 92 is formed of a unitary piece of metal and includes upper and lower inwardly facing engagement surfaces 94 , 96 , and a top 98 , and left and right sides 100 , 102 . The upper engagement surface 94 is rectangular. The lower engagement surface preferably is trapezoidal wherein an edge 104 of the lower surface is disposed adjacent to the middle portion 82 of the pedal lever 28 . The engagement surfaces 94 , 96 slightly angle together to form an outwardly facing obtuse angle. The inward surface of both the upper and lower engagement surfaces 94 , 96 can be engaged with the operator's foot for operation of the deck lift mechanism 10 . Preferably, the inward surfaces have attached an abrasive material, or high friction material such as rubber, to reduce slippage of the operator's foot. The top 98 and left and right sides 100 , 102 perpendicularly extend outwardly form the upper engagement surface 94 to partially enclose the pedal lever upper portion 84 .
[0040] The operation of the preferred embodiment will now be discussed. To place the deck 12 in the transport position, the operator places their right foot on the pedal 92 wholly retaining their hands on the drive controls and remaining seated on the vehicle seat. As the operator depresses the pedal lever 28 with their foot, the foot and rear lift shafts 22 , 24 rotate causing the outer end of the deck lift levers 72 to radially rise upwards. The deck 12 , carried by the chains 76 attached to the deck lift levers 72 , is lifted upwards. Alternatively, the deck can be placed in the transport position by the operator moving the lift lever 14 backwards, or using a combination of the lift lever 14 and the pedal lever 28 .
[0041] Simultaneously, upon engagement of the pedal lever, the rotating front lift shaft 22 transmits movement to the lift lever 14 through the pair of lift linkages 20 . As the lift lever 14 pivots the lift pin 42 , carried by the lift lever 14 , radially moves rearward sliding atop the top rail 62 towards the transport opening 64 provided in the top rail 62 . Sufficiently depressing the pedal lever 28 moves the lift lever 14 , which carries the lift pin 42 where the potential energy of the spring 40 forces the biased lift pin 42 into the transport opening 64 . The lift pin 42 sufficiently extends into the transport opening 64 so as not to be inadvertently removed or jostled therefrom, yet require minimal lifting to be removed from the transport opening 64 . When fully inserted into the transport opening 64 , the lift pin 42 extends between ⅛ and 1½ inches therein, and preferably between ¼ and ¾ inch. The lift pin 42 fits within the transport opening 64 with little lateral play. When the lift pin 42 is within the transport opening 64 , the deck 12 is in the transport position corresponding to about a six-inch cutting height.
[0042] The deck can alternatively be placed in the transport position by the operator grasping the handle 33 with their right hand and pulling the lift lever 14 backwards, until the lift pin 42 reaches the transport opening. Similarly, the operator can simultaneously pull the handle 33 and depress the pedal lever 28 to place the deck into the transport position, which supports the deck at the desired cutting height.
[0043] To remove the deck 12 from the transport position to a cutting position, the height adjustment pin 66 is inserted into a pair of coaxially aligned openings 58 that correspond to the desired cutting height. Then, the operator places their palm on the handle 33 with fingers extending downward grasping the lift pin 42 . The operator applies moderate pressure to the pedal 92 and/or handle 33 to offset the weight of the deck 12 , thereby, reducing the force required to remove the lift pin 42 from the transport opening 64 . The operator closes their hand forcing the lift pin 42 upwards and out of the transport opening 64 . The lift lever 14 pivotally rotates forward under the weight of the deck 12 , partially offset by the operator, until contacting the height adjustment pin 66 , and consequently setting or re-setting the cutting deck position.
[0044] The cutting deck may be vertically adjusted for a plurality of cutting height settings. If the cutting deck is locked in its uppermost transport position, it may then be returned to the pre-selected cutting height set by the height adjustment pin once removed it is from the transport position.
[0045] Although the invention has been shown and described with respect to certain embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon reading and understanding of the specification. The present invention includes all such equivalent alterations and modifications, and is limited only by the scope of the claims. | An apparatus for lifting a deck of a vehicle, such as a lawn mower, by a foot actuated deck lift mechanism. The device includes a lift lever pivotally coupled to a frame and having a pin movably attached thereto. A lift linkage has a first end pivotally coupled to the lift lever and a second end fixedly secured on a front shaft. A connecting linkage pivotally couples the front shaft to a rear shaft. Both the front and rear shafts are rotatably coupled to the frame. The lift lever has a first end fixedly secured to the front shaft and a second free end for operation with the operator's foot. The deck is attached to the deck lift mechanism. A foot actuated deck lift mechanism, depressed by the operator's foot, and simultaneously causes the deck to rise and the lift lever to radially pivot. A pin attached to the lift lever rides atop adjustment plates. When the lift lever has pivoted a preset amount, an opening provided in the adjustment plates receives the pin. The pin then locks the deck at a height suitable for transporting the vehicle. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to work areas and workshops, and more particularly, to a portable, compact folding workshop which includes an enclosure or cubicle defined by multiple, hinged panels which support cabinets, shelves, lighting and pegboards for storing tools, equipment and supplies. The panels forming the enclosure can be locked to secure the tools, equipment and supplies inside the enclosure when the workshop is in folded configuration and is not in use. In a preferred embodiment of the invention the enclosure is open at the top and bottom and consists of four panels mounted on rollers to more easily facilitate moving of the enclosure and opening of the panels on the connecting hinges to provide access to the cabinets and shelves, and to the tools, equipment and supplies, for functional use of the workshop. When in folded, stored configuration the portable workshop occupies a relatively small space and can be easily deployed in a garage or carport or even in the corner of a room inside the home, and when deployed for use the work area is no larger than a conventional work bench of similiar facility. The portable workshop of this invention is designed to provide maximum expediency in the use of hand and power tools in a workshop environment which occupies minimum space.
2. Description of the Prior Art
Efforts to conserve space by using portable furniture and other folding, compact items of a functional or decorative nature are well known in the prior art. U.S. Pat. No. 150,194, to H. J. Barrett, discloses a "Folding, Portable Bar" which includes a central portion having folding side members in order to facilitate storage of the bar in a minimum of space. A similiar "Portable Bar" is disclosed in U.S. Pat. No. 2,260,586 to R. I. Sheldon, which bar is characterized by a center support having hinged drop leaves supported by outwardly extending side members. U.S. Pat. No. 1,348,073, to M. P. Almy, discloses a portable screen which is likewise comprised of a central support member having shelves therein and folding wings or outer portions to facilitate use of the screen in functional position with the wings unfolded, and in storage configuration, with the wings in folded position against the center portion. U.S. Pat. No. 3,353,885, to H. C. Hanson, discloses an "Expansible Multi-Purpose Cabinet" which includes telescoping cabinet portions which can be slidably displaced to provide a work area, with accessory members which unfold and open to deploy a mirror and provide access to interior shelves within the major support members. A similiar "Display Case" is disclosed in U.S. Pat. No. 1,336,899, to W. H. Gallagher, which display case includes a central support member having interior shelves and outwardly folding side members or wings which can be unfolded and deployed on hinges for decorative purposes. French Pat. No. 1,444,175 discloses a folding cabinet having multiple interior storage compartments and two major folding portions which are hinged at one edge and open to provide access to the interior compartments. The major cabinet members close on the hinges to facilitate storage of the cabinet in a minimum of space. U.S. Pat. No. 2,870,459, to R. F. Zabielski, discloses an item of folding furniture which includes a major support member having a pair of folding side members hingedly attached at opposite edges, with one of the side members further including shelves and a hinged desk top and supporting doors which open beneath the desk top to support the desk top when in functional position. One or more cots can be deployed from storage in the major support member between the two folding side members when the folding side members are deployed on the hinges away from the major support member.
In recent years due to the high rate of inflation and increased costs, there has been a growing trend toward economy of space and the undertaking of home projects individually, rather than by use of skilled labor provided by contractors. This trend is particularly noteworthy with regard to the "do it yourself" home projects, which usually require a work space or area of sufficient size to handle the projects in question. Since the average home contains little extra space to accommodate such projects, they sometimes go unattended, or must be accomplished by skilled labor at a high cost.
Accordingly, it is an object of this invention to provide a new and improved, portable, compact workshop which is characterized by an enclosure or cubicle formed of multiple, hinged panels, which enclosure, when in folded, stored configuration, can be closed and locked or otherwise secured, and can be opened to provide access to cabinets, shelves, work space and tools contained within the enclosure.
Another object of this invention is to provide a new and improved portable workshop having an enclosure characterized by an open top and bottom and having multiple, hinged panels mounted on rollers to facilitate moving of the enclosure and opening and closing of the panels, which enclosure, in functional configuration, opens to provide access to shelves and cabinets mounted in cooperation with the supporting panels, and in closed configuration, can be locked to secure tools, supplies and materials within the enclosure.
Yet another object of the invention is to provide a new and improved workshop which is characterized by a cubicle-type enclosure defined by four hinged panels mounted on rollers and adapted for locking or securing into the cubicle configuration when not in use in order to conserve space, and which opens into a generally linear spatial arrangement to provide access to pegboards, cabinets, shelves, and a horizontal work space attached to the panels.
Yet another object of the invention is to provide a new and improved portable, compact workshop which can be stored in a minimum of space and used substantially anywhere, and which in a preferred embodiment is characterized by an enclosure shaped by four hinged, wheeled panels of substantially the same size which can be closed to secure tools and materials inside the enclosure when in stored configuration, and opened into a substantially linear arrangement on the hinges when in functional configuration, to provide access to shelves, cabinets, and a horizontal work space which is extended by a hinged counter adapted to be folded into a substantially horizontal position between cabinets attached to the panels.
SUMMARY OF THE INVENTION
These and other objects of the invention are provided in a new and improved, portable and compact workshop which is characterized by an enclosure or cubicle defined by four hinged panels, two of which panels are hinged together along adjacent edges and are each provided with a panel facing disposed along the opposite edges for hinged attachment to the other panels, which panels can be folded on the hinges into an open top and bottom cubicle in stored configuration, and opened into a substantially linear spatial arrangement to provide access to shelves, cabinets and pegboards attached to the panels and containing tools and supplies, when in functional configuration. In a preferred embodiment the panels are mounted on rollers and are provided with a folding counter spanning the cabinets to increase the available horizontal work area.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood by reference to the accompanying drawings wherein:
FIG. 1 is a perspective view of a preferred embodiment of the portable workshop in folded configuration;
FIG. 2 is a perspective view of the portable workshop illustrated in FIG. 1, with one of the four hinged panels in open configuration;
FIG. 3 is a perspective view of the portable workshop illustrated in FIGS. 1 and 2, with the panels further deployed on hinges to a partially open configuration;
FIG. 4 is a front elevation of the portable workshop, with the panels deployed in a fully open, linear and functional configuration;
FIG. 5 is a front elevation, partially in section, of the door panel of the portable workshop;
FIG. 6 is a perspective view, partially in section, of a preferred work support leg and brace design for a work support member;
FIG. 7 is a perspective view, partially in section, of a preferred folding counter for extending the horizontal working area in the portable workshop; and
FIG. 8 is a sectional view, taken along lines 8--8 in FIG. 4, more particularly illustrating the folding counter design.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 of the drawings, the portable workshop of this invention is generally illustrated by reference numeral 1, and is illustrated in folded, stored configuration where it occupies a minimum of space. Portable workshop 1 includes an enclosure or cubicle, generally illustrated by reference numeral 2, which is defined by a door panel 3 and a cooperating closure panel 8, which are both mounted on rollers 14, as illustrated. A set of three hasps 6, are each hingedly attached in spaced relationship to the unhinged edge of closure panel 8, and a lock 7 secures the center one of hasps 6 to a conventional eyelet secured to the door panel 3, in conventional fashion. In a preferred embodiment of the invention the door panel 3 is attached to a panel facing 4 by means of panel hinges 5, closure panel 8 is in turn attached to a second panel facing 4, by means of additional panel hinges 5, and each panel facing 4 is rigidly secured to one of rear panels 9, respectively, which are hinged together at adjacent edges, as hereinafter described.
Referring now to FIGS. 2 and 3 in sequence, the door panel 3 and closure panel 8 are partially opened on panel hinges 5, and rear panel hinges 10 are illustrated as attached to the inside surfaces of rear panels 9, to facilitate closing and opening of the rear panels 9. In a most preferred embodiment of the invention the rear panels 9 are each provided with a pegboard 12 on the inside surfaces and a single cabinet 16 is attached to one of the rear panels 9, while a double cabinet 19 is attached to the opposite one of rear panels 9, as illustrated in FIG. 3. Furthermore, shelves 34 are secured to the inside surfaces of door panel 3 and closure panel 8, respectively, and a pair of lights 13, are mounted on the rear panels 9 above the pegboards 12. Single cabinet 16 is provided with a horizontially-mounted single cabinet top 21, and the double cabinet 19 includes a double cabinet top 20 in substantially the same plane as single cabinet top 21, to provide divided horizontal work spaces when the portable workshop 1 is fully deployed, as hereinafter described. Both the single cabinet 16 and double cabinet 19 are provided with cabinet compartments 17 for storage of tools, supplies and equipment, as deemed expedient by the user. Furthermore, in a preferred embodiment the single cabinet 16 is also provided with a drawer 18 for additional storage capacity.
Referring now to FIGS. 1-4 of the drawings, in another most preferred embodiment of the invention the rollers 14 are secured to roller mounts 15, which are attached to the door panel 3, closure panel 8 and the rear panels 9, respectively, and rollers 14 are also provided on the bottom of single cabinet 16 and double cabinet 19, to more easily facilitate moving the portable workshop, both from one location to another and from the closed to the open configuration, and back to the closed mode, as illustrated in the opening sequence in FIGS. 1-4.
Referring now to FIGS. 2, 3, 4 and 7 of the drawings, in yet another most preferred embodiment of the invention, a hinged counter 23 is provided in the portable workshop 1 to make available a horizontal work space or area between the double cabinet top 20 of double cabinet 19 and the single cabinet top 21, of single cabinet 16. The counter 23 is attached to the single cabinet 16 by means of a counter hinge 29, and counter 23 can be deployed on counter hinge 29 from a non-functional position rearwardly toward single cabinet top 21, to a substantial alignment with double cabinet top 20 and single cabinet top 21. When so disposed in functional position, the counter 23 rests on the counter support 30, attached to double cabinet 19, as illustrated in FIGS. 4 and 7. In order to facilitate a full range of motion from a functional position in alignment with the double cabinet top 20 and the single cabinet top 21 as illustrated in FIG. 4, the counter 23 includes a counter segment 24, which is attached to the counter 23 by means of a counter segment hinge 25. A handle 28 is attached to the counter segment 24 to provide a means for manipulating the counter segment 24 on the counter segment hinge 25, to permit counter 23 to clear the pegboard 12 located above single cabinet 16, as the counter 23 moves in an arc past the pegboard 12, and past any tool or tools which may be suspended on the pegboard 12 in the arc. In another most preferred embodiment of the invention a cabinet spacer 31 is removably provided in spacer brackets 32, located on single cabinet 16 and double cabinet 19, respectively. The cabinet spacer 31 serves to maintain the proper distance between single cabinet 16 and double cabinet 19 when the portable workshop 1 is in deployed and functional configuration, as illustrated in FIG. 4, in order that counter 23 might be hingedly folded to bridge the distance between double cabinet top 20 and single cabinet top 21.
Referring again to FIG. 4 of the drawing, when the portable workshop 1 is in fully deployed and functional configuration, easy access is provided to the cabinet compartments 17 in single cabinet 16 and double cabinet 19, to the drawer 18 in single cabinet 17, and to the shelves 34 and the pegboards 12, for efficient use of the portable workshop 1.
In yet another preferred embodiment, electrical boxes 35 are provided above the double cabinet top 20 and single cabinet top 21, respectively, and mounted on each panel facing 4, in order to conveniently make use of power tools. Wiring 36, illustrated in phantom, connects the electrical boxes 35 with a central plug 22, illustrated in FIG. 1, which can be plugged into an extension cord or other conduit to supply electricity to the portable workshop 1.
Referring now to FIGS. 5 and 6 of the drawing, in a still further preferred embodiment of the invention the work support legs 37 and work support brace 38 of an auxiliary work support 33 are mounted on door panel 3, and work support 33 can be assembled from work support legs 37 and the cooperating work support brace 38, as illustrated in FIG. 6, to provide an additional working surface for use in connection with the portable workshop 1. As further illustrated in FIG. 6 the work support brace 38 is provided with brace ribs 40, which are spaced to register with a cooperating leg slot 39, provided in work support legs 37, to shape and support each end of the work support 33.
Referring again to the drawings, it will be appreciated by those skilled in the art that the portable workshop 1 can be shaped from multiple panels to provide a geometric enclosure of desired character. However, in a most preferred embodiment, four such panels are used, and the door panel 3, with the cooperating panel facing 4, the closure panel 8, also with the adjacent panel facing 4, and each of the rear panels 9 are about 4 feet by 8 feet in size respectively, to define an enclosure 2 which occupies a space of about 16 square feet when in folded configuration. Furthermore, various desired sizes, configurations and locations of shelves 34 and pegboards 12 can be provided inside the portable workshop 1 and mounted to the door panel 3, closure panel 8 and the rear panels 9, respectively, according to the particular needs and desires of the user. For example, while the lights 13 are illustrated as florescent lighting in the drawings, it will be appreciated that incandescent lights or other lighting known to those skilled in the art, can also be used as desired. Furthermore, the location, number and size of the single cabinet 16 and double cabinet 19 can also be varied to suit the particular needs of the user. However, in a most preferred embodiment of the invention it has been found that the specific spatial orientation of the utility means, such as the single cabinet 16 and double cabinet 19 on the rear panels 9, respectively, illustrated in the drawings is particularly advantageous when used in cooperation with the folding counter 23, to provide maximum horizontal work space and still facilitate the folding function of the portable workshop 1. Other utility means and modifications, which include a second work support 33 attached to the inside surface of the closure panel 8, and a vise secured to the double cabinet top 20 or single cabinet top 21, as well as storage jars or receptacles carried by the shelves 34, can be provided, in non-exclusive particular, according to the knowledge of those skilled in the art.
As heretofore described, the portable workshop of this invention can be used both outside and inside the home, and is particularly well adapted for garage and carport use in homes which are either sparsely provided with, or are not equipped with a workshop, work bench or storage facilities such as cabinets, shelves and pegboards, to accommodate tools, supplies and equipment. The portable workshop can be completely deployed in linear configuration, as illustrated in FIG. 4 of the drawings, or it can be partially opened, as illustrated in FIGS. 2 and 3 to provide shelter from wind in cold weather when the workshop is used outside.
While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention. | A portable, compact and fully equipped workshop which includes enclosure or cubicle characterized by four hinged panels mounted on rollers and containing interior cabinets, shelves and lighting, and further including a hinged counter positioned inside the enclosure and raised when the panels are in folded configuration. The counter can be deployed in horizontal position to provide additional work space when the panels are opened to provide access to the cabinets and shelves. Various hand and power tools, as well as miscellaneous supplies and equipment can be stored in compartments provided in the cabinets and on the shelves, and the panels can be locked into the folded configuration to secure the tools, supplies and equipment inside the enclosure. | 1 |
[0001] The present invention relates to combinations of compounds of the class having the formula (I) as defined below, for example compounds of the xanthenone acetic acid class having the formula (II) as defined below, such as 5,6-dimethylxanthenone-4-acetic acid (DMXAA), or a pharmaceutically acceptable salt, ester or prodrug thereof and EGFR signalling pathway inhibitors. For example, the present invention relates to synergistic combinations of compounds of the class having the formula (I) as defined below, for example compounds of the xanthenone acetic acid class having the formula (II) as defined below, such as 5,6-dimethylxanthenone-4-acetic acid (DMXAA), or a pharmaceutically acceptable salt, ester or prodrug thereof and EGFR signalling pathway inhibitors. More particularly, the invention is concerned with the use of such combinations in the treatment of cancer. The present invention also relates to pharmaceutical compositions containing such combinations.
[0002] 5,6-dimethylxanthenone-4-acetic acid (DMXAA) is represented by the following formula:
[0000]
[0003] Three phase I clinical trials of DMXAA as a monotherapy have recently been completed, with dynamic MRI showing that it induces a significant reduction in tumour blood flow at well-tolerated doses. DMXAA is thus one of the first vascular disrupting agents (VDAs) for which activity (irreversible inhibition of tumour blood flow) has been documented in human tumours. These findings are in agreement with preclinical studies using syngeneic murine tumours or human tumour xenografts, which showed that its antivascular activity produced prolonged inhibition of tumour blood flow leading to extensive regions of haemorrhagic necrosis.
[0004] However, in these phase I clinical trials of DMXAA there were very few tumour responses, demonstrating that DMXAA alone does not have significant potential in cancer treatment as a single agent. Therefore, there is a need to identify compounds that could have a synergistic effect with DMXAA.
[0005] There is a new class of cancer drugs available that are not cytotoxics, but block the epidermal growth factor signalling pathways. Examples include Erbitux™ (cetuximab), a monoclonal antibody binding to epidermal growth factor receptor (EGFR) and Tarceva™ (erlotinib) and Iressa™ (gefitinib), small molecules that inhibit cell signalling in the EGFR pathway. We have surprisingly found that DMXAA may act synergistically with these new agents, enhancing their anti-cancer activity.
EGFR Signalling Pathway Inhibitors
[0006] Tumours have been found to overexpress certain growth factors that enable them to proliferate rapidly, one of which is EGF. Activation of EGFR by binding of EGF and formation of an active receptor dimer induces phosphorylation of the tyrosine kinase in the intracellular domain of the receptor. The ras protein initiates a cascade of phosphorylations which result in activation of mitogen activated protein kinase (MAPK). MAPK triggers events in the nucleus that result in cell division. As a result, overexpression of EGF, or of EGFR on the cell surface can result in uncontrolled cell division characteristic of cancer. Expression levels of EGF and EGFR are negatively correlated with prognosis and survival in cancer, and inhibiting the signalling pathway has been shown to improve survival.
[0007] The EGFR pathway is targeted by Erbitux™ (cetuximab, a chimeric monoclonal antibody marketed for colorectal cancer by Imclone and Bristol-Myers Squibb in the US and Schering in Europe), which binds to EGF receptors, blocking EGF from binding to them. Tarceva™ (erlotinib, marketed by Genentech and OSI Pharmaceuticals in the US and Roche elsewhere) and Iressa™ (gefitinib, marketed by AstraZeneca), small molecules marketed for non-small cell lung cancer, inhibit phosphorylation of the intracellular tyrosine kinase, interfering with cell signalling. This limits the uncontrolled cell division caused by overstimulation of the EGFR signalling pathway.
[0008] Of the EGFR signalling pathway inhibitors, only Tarceva™ has demonstrated a survival advantage in phase III trials, with both Erbitux™ and Iressa™ being approved based on tumour response rates. Since its approval Iressa™ has completed a number of phase III trials, which found that it did not extend median survival, despite the improvement in response rate over standard care.
Previous EGFR Signalling Pathway Inhibitor Combination Studies
[0009] Clinical trials of the EGFR signalling pathway inhibitors do not suggest that they are likely to show synergy with vascular targeting anti-cancer agents. Erbitux™ is approved for use as a monotherapy or in combination with irinotecan, a non-vascular targeting cytotoxic.
[0010] Both Iressa™ and Tarceva™ have been tested with combinations that include paclitaxel, a compound known to have anti-angiogenic properties secondary to its cytotoxic activity, with no evidence of benefit. For both products, two trials failed to show a benefit of adding the EGFR signalling inhibitor to standard chemotherapy. Iressa™ is indicated only as a monotherapy because two large, controlled, randomised trials showed it to give no survival benefit when used first-line in combination with chemotherapy that included a platin and another agent, which could be paclitaxel. Tarceva™ has been similarly unsuccessful in demonstrating a survival benefit when combined with carboplatin/paclitaxel or cisplatin/gemcitabine. Tarceva™ has demonstrated a survival benefit in pancreatic cancer patients when combined with gemcitabine, a non-vascular targeting cytotoxic cancer drug.
Previous DMXAA Combination Studies
[0011] DMXAA has previously been demonstrated to have synergy with a number of agents in xenograft studies. These agents include widely used cytotoxic chemotherapies such as taxanes (paclitaxel and docetaxel), platins (cisplatin and carboplatin), vinca alkaloids (vincristine), antimetabolites (gemcitabine), topoisomerase II inhibitors (etoposide) and anthracyclines (doxorubicin). It is believed that the synergy arises because DMXAA causes necrosis in the centre of tumours, but seems to leave a viable rim of cancer cells. These are targeted by the cytotoxic agents which primarily act on rapidly proliferating cells. None of these chemotherapy agents are known to affect the EGFR signalling pathway.
[0012] DMXAA is currently in two phase II trials examining its anti-tumour efficacy in combination with paclitaxel and carboplatin, and one trial combining it with docetaxel. The cytotoxic effect of the taxanes is caused by interference with tubulin, which prevents normal mitosis (cell division). A secondary effect is disruption of newly formed blood vessels, since the cells of the new vascular endothelium depend on tubulin to maintain their shape. However, the cytotoxic effect is overriding at higher doses, such as those used in chemotherapy. Any synergy between DMXAA and the taxanes is thought to be a result of the targeting of different parts of the tumour, as described above.
[0013] Other agents have also been shown to enhance the activity of DMXAA in xenograft studies. Although the exact mechanism of action of DMXAA is not understood, it is believed to cause upregulation of various cytokines, and compounds with similar activity appear to enhance its effectiveness. These include tumour necrosis factor stimulating compounds and immunomodulatory compounds such as intracellular adhesion molecules (ICAMs).
[0014] Diclofenac, an NSAID that has been shown to enhance the anti-tumour activity of DMXAA, is believed to affect the PK of DMXAA via competition for metabolic pathways. At a concentration of 100 μM, diclofenac has been shown to significantly inhibit glucoronidation (>70%) and 6-methylhydroxylation (>54%) of DMXAA in mouse and human liver microsomes. In vivo, diclofenac (100 mg/kg i.p.) has been shown to result in a 24% and 31% increase in the plasma DMXAA AUC (area under the plasma concentration-time curve) and a threefold increase in T 1/2 (P<0.05) in male and female mice respectively (see Zhou et al. (2001) Cancer Chemother. Pharmacol. 47, 319-326). Other NSAIDs have been shown to have a similar effect.
[0015] Similarly to diclofenac, thalidomide, which is approved for erythema nodosum leprosum (ENL), seems to enhance the activity of DMXAA. Thalidomide is also known to have anti-angiogenic effects but the synergy is caused by effect on metabolism of DMXAA. It competes for glucuronidation, prolonging DMXAA's presence at therapeutic levels in tumour tissue. Thalidomide increases the AUC of DMXAA by 1.8 times in plasma, liver and spleen and by three times in tumour (see Kestell et al. (2000) Cancer Chemother. Pharmacol. 46(2), 135-41).
DESCRIPTION OF THE INVENTION
[0016] In a first aspect, the present invention provides a method for modulating neoplastic growth, which comprises administering to a mammal, including a human, in need of treatment an effective amount of formula (I):
[0000]
[0000] wherein:
(a) R 4 and R 5 together with the carbon atoms to which they are joined, form a 6-membered aromatic ring having a substituent —R 3 and a radical —(B)—COOH where B is a linear or branched substituted or unsubstituted C 1 -C 6 alkyl radical, which is saturated or ethylenically unsaturated, and wherein R 1 , R 2 and R 3 are each independently selected from the group consisting of H, C 1 -C 6 alkyl, halogen, CF 3 , CN, NO 2 , NH 2 , OH, OR, NHCOR, NHSO 2 R, SR, SO 2 R or NHR, wherein each R is independently C 1 -C 6 alkyl optionally substituted with one or more substituents selected from hydroxy, amino and methoxy; or
[0018] (b) one of R 4 and R 5 is H or a phenyl radical, and the other of R 4 and R 5 is H or a phenyl radical which may optionally be substituted, thenyl, furyl, naphthyl, a C 1 -C 6 alkyl, cycloalkyl, or aralkyl radical; R 1 is H or a C 1 -C 6 alkyl or C 1 -C 6 alkoxy radical; R 2 is the radical —(B)—COOH where B is a linear or branched substituted or unsubstituted C 1 -C 6 alkyl radical, which is saturated or ethylenically unsaturated,
[0000] or a pharmaceutically acceptable salt, ester or prodrug thereof and concomitantly or sequentially administering an EGFR signalling pathway inhibitor.
[0019] Where (B) in the radical —(B)—COOH is a substituted C 1 -C 6 alkylene radical, the substituents may be alkyl, for example methyl, ethyl, propyl or isopropyl, or halide such as fluoro, chloro or bromo groups. In one example the substituent is methyl.
[0020] In one embodiment of the first aspect of the invention, the compound of the formula (I) as defined above may be a compound of the formula (II):
[0000]
[0000] where R 1 , R 4 , R 5 and B are as defined above for formula (I) in part (b).
[0021] In a further embodiment of the first aspect of the invention, the compound of formula (I) as defined above may be a compound of the formula (III):
[0000]
[0000] wherein R 1 , R 2 and R 3 are each independently selected from the group consisting of H, C 1 -C 6 alkyl, halogen, CF 3 , CN, NO 2 , NH 2 , OH, OR, NHCOR, NHSO 2 R, SR, SO 2 R or NHR, wherein each R is independently C 1 -C 6 alkyl optionally substituted with one or more substituents selected from hydroxy, amino and methoxy;
wherein B is as defined for formula (I) above;
and wherein in each of the carbocyclic aromatic rings in formula (I), up to two of the methine (—CH═) groups may be replaced by an aza (—N═) group;
and wherein any two of R 1 , R 2 and R 3 may additionally together represent the group —CH═CH—CH═CH—, such that this group, together with the carbon or nitrogen atoms to which it is attached, forms a fused 6-membered aromatic ring.
[0022] For example, the compound of formula (III) may be a compound of the formula (IV):
[0000]
[0000] wherein R, R 1 , R 2 and R 3 are as defined for formula (III).
[0023] In one embodiment of the compound of formula (IV), R 2 is H, one of R 1 and R 3 is selected from the group consisting of C 1 -C 6 alkyl, halogen, CF 3 , CN, NO 2 , NH 2 , OH, OR, NHCOR, NHSO 2 R, SR, SO 2 R or NHR, wherein each R is independently C 1 -C 6 alkyl optionally substituted with one or more substituents selected from hydroxy, amino and methoxy, and the other of R 1 and R 3 is H.
[0024] For example, the compound of formula (IV) may be of the formula (V):
[0000]
[0000] wherein R, R 1 , R 2 and R 3 are as defined for formula (IV).
[0025] The compound of formula (V) may be, for example, 5,6-dimethylxanthenone-4-acetic acid (DMXAA), or a pharmaceutically acceptable salt, ester or prodrug thereof.
[0026] In one embodiment of the invention the EGFR signalling pathway inhibitor is a monoclonal antibody.
[0027] In one embodiment of the invention the EGFR signalling pathway inhibitor is Erbitux™ (cetuximab).
[0028] In one embodiment of the invention the EGFR signalling pathway inhibitor is a tyrosine kinase inhibitor.
[0029] In one embodiment of the invention the EGFR signalling pathway inhibitor is Tarceva™ (erlotinib).
[0030] In one embodiment of the invention the EGFR signalling pathway inhibitor is Iressa™ (gefitinib).
[0031] In another aspect, the present invention provides the use of a EGFR signalling pathway inhibitor for the manufacture of a medicament (e.g. of a unit dose of a medicament), for simultaneous, separate or sequential administration with the compound of formula (I) as defined above or a pharmaceutically acceptable salt, ester or prodrug thereof (e.g. a unit dose of the compound of formula (I) as defined above or a pharmaceutically acceptable salt, ester or prodrug thereof), for the modulation of neoplastic growth.
[0032] In another aspect, the present invention provides the use of the compound of formula (I) as defined above or a pharmaceutically acceptable salt, ester or prodrug thereof for the manufacture of a medicament (e.g. a unit dose of a medicament) for simultaneous, separate or sequential administration with the EGFR signalling pathway inhibitor (e.g. a unit dose of the EGFR signalling pathway inhibitor) for the modulation of neoplastic growth.
[0033] According to one aspect, the neoplastic growth is a tumour and/or a cancer.
[0034] In a further aspect, the neoplastic growth is one or more of ovarian, prostate, lung, pancreatic, colorectal, and head and neck cancer.
[0035] In a further aspect, there is provided a pharmaceutical formulation comprising a combination of the compound of formula (I) as defined above or a pharmaceutically acceptable salt, ester or prodrug thereof (e.g. in a unit dose) and an EGFR signalling pathway inhibitor (e.g. in a unit dose).
[0036] In one embodiment there is provided a compound according to formula (I) or a pharmaceutically acceptable salt, ester or prodrug thereof and an EGFR signalling pathway inhibitor for use (in combination) as a medicament for modulation of neoplastic growth.
[0037] The invention further provides a process for the preparation of a pharmaceutical formulation which process comprises bringing into association a combination of the compound of formula (I) as defined above or a pharmaceutically acceptable salt, ester or prodrug thereof (e.g. a unit dose of the compound of formula (I) as defined above or a pharmaceutically acceptable salt, ester or prodrug thereof) and an EGFR signalling pathway inhibitor (e.g. a unit dose of the EGFR signalling pathway inhibitor), optionally with one or more pharmaceutically acceptable carriers therefor. For example, the pharmaceutical formulation may be in a unit dose.
[0038] Pharmaceutical formulations comprise the active ingredients (that is, the combination of a compound of formula (I) as defined above or pharmaceutically acceptable salt, ester or prodrug thereof and the growth factor inhibitor, for example EGFR signalling pathway inhibitor), for example together with one or more pharmaceutically acceptable carriers therefor and optionally other therapeutic and/or prophylactic ingredients. The carrier(s) must be acceptable in the sense of being compatible with the other ingredients in the formulation and not deleterious to the recipient thereof.
[0039] The compound of formula (I) as defined above or a pharmaceutically acceptable salt, ester or prodrug thereof and the EGFR signalling pathway inhibitor may be administered simultaneously, separately or sequentially.
[0040] In one embodiment, the pharmaceutically acceptable salt is a sodium salt.
[0041] The amount of a combination of a compound of formula (I) as defined above or pharmaceutically acceptable salt, ester or prodrug thereof and an EGFR signalling pathway inhibitor required to be effective as a modulator of neoplastic growth will, of course, vary and is ultimately at the discretion of the medical practitioner. The factors to be considered include the route of administration and nature of the formulation, the mammal's bodyweight, age and general condition and the nature and severity of the disease to be treated.
[0042] A suitable effective dose of a compound of formula (I) as defined above, or a pharmaceutically acceptable salt thereof, for administration, simultaneously, separately or sequentially, with an EGFR signalling pathway inhibitor, for the treatment of cancer is in the range of 600 to 4900 mg/m 2 . For example from 2500 to 4000 mg/m 2 , from 1200 to 3500 mg/m 2 , more suitably from 2000 to 3000 mg/m 2 , particularly from 1200 to 2500 mg/m 2 , more particularly from 2500 to 3500 mg/m 2 , preferably from 2250 to 2750 mg/m 2 .
[0043] It is of course also possible to base dosages upon the weight of a patient. For example, a dosage of a compound of formula (I) as defined above, or a pharmaceutically acceptable salt thereof, for administration, simultaneously, separately or sequentially, with an EGFR signalling pathway inhibitor, for the treatment of cancer may be in the range of 15 to 125 mg/kg body weight may be administered. More preferably, the dosage is from 30 to 80 mg/kg, or 30 to 70 mg/kg.
[0044] In one embodiment the Erbitux™ may be administered in a loading dose of 250 to 500 mg/m 2 (e.g. about 400 mg/m 2 ) and then weekly doses of 150 to 350 mg/m 2 (e.g. about 250 mg/m 2 ).
[0045] As above, the dosage for Erbitux™ may be based upon the weight of a patient. For example, Erbitux™ may be administered in a loading dose of 6 to 13 mg/kg (e.g. about 10 mg/kg) and then weekly doses of 4 to 9 mg/kg (e.g. about 6 mg/kg).
[0046] In one embodiment the Iressa™ and Tarceva™ may be administered in an amount of one 100 to 350 mg tablet daily. For example, Iressa™ may be administered in an amount of one 250 mg tablet daily, and the Tarceva™ may be administered in an amount of one 150 mg tablet daily.
[0047] The pharmaceutical formulation may be delivered intravenously (e.g. a formulation containing Erbitux™) or orally (e.g. a formulation containing Iressa™ or Tarceva™). The pharmaceutical composition for intravenous administration may be used in the form of sterile aqueous solutions or in an oleaginous vehicle which may contain other substances, for example, enough salts or glucose to make the solution isotonic with blood. The aqueous solutions may be buffered (e.g. to a pH from 3 to 9), if necessary.
[0048] The pharmaceutical formulations (e.g. containing Iressa™ or Tarceva™) may, for example, be administered orally in one or more of the forms of tablets, capsules, ovules, elixirs, solutions or suspensions, which may contain flavouring or colouring agents, for immediate-, delayed-, modified-, sustained-, pulsed- or controlled-release applications.
[0049] If the pharmaceutical formulation is a tablet, then the tablet may contain excipients such as microcrystalline cellulose, lactose, sodium citrate, calcium carbonate, dibasic calcium phosphate and glycine, disintegrants such as starch (preferably corn, potato or tapioca starch), sodium starch glycollate, croscarmellose sodium and certain complex silicates, and granulation binders such as polyvinylpyrrolidone, hydroxypropylmethylcellulose (HPMC), hydroxypropylcellulose (HPC), sucrose, gelatin and acacia. Additionally, lubricating agents such as magnesium stearate, stearic acid, glyceryl behenate and talc may be included.
[0050] Solid formulations of a similar type may also be employed as fillers in gelatin capsules. Preferred excipients in this regard include lactose, starch, cellulose, milk sugar or high molecular weight polyethylene glycols. For aqueous suspensions and/or elixirs, the compound may be combined with various sweetening or flavouring agents, colouring matter or dyes, with emulsifying and/or suspending agents and with diluents such as water, ethanol, propylene glycol and glycerin, and combinations thereof.
[0051] Pharmaceutical formulations suitable for oral administration may, where appropriate, be conveniently presented in discrete dosage units and may be prepared by any of the methods well known in the art of pharmacy. All methods include the step of bringing into association the active ingredients with liquid carriers or finely divided solid carriers or both and then, if necessary, shaping the product into the desired formulation.
[0052] Pharmaceutical formulations suitable for oral administration wherein the carrier is a solid are most preferably presented as unit dose formulations such as boluses, capsules or tablets each containing a predetermined amount of the active ingredients. A tablet may be made by compression or moulding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing in a suitable machine the active compounds in a free-flowing form such as a powder or granules optionally mixed with a binder, lubricant, inert diluent, lubricating agent, surface-active agent or dispersing agent. Moulded tablets may be made by moulding an inert liquid diluent. Tablets may be optionally coated and, if uncoated, may optionally be scored. Capsules may be prepared by filling the active ingredients, either alone or in admixture with one or more accessory ingredients, into the capsule shells and then sealing them in the usual manner. Cachets are analogous to capsules wherein the active ingredients together with any accessory ingredient(s) are sealed in a rice paper envelope. The compound of formula (I) or a pharmaceutically acceptable salt or ester may also be formulated as dispersible granules, which may for example be suspended in water before administration, or sprinkled on food. The granules may be packaged e.g. in a sachet.
[0053] The active ingredients may also be formulated as a solution or suspension for oral administration. Formulations suitable for oral administration wherein the carrier is a liquid may be presented as a solution or a suspension in an aqueous liquid or a non-aqueous liquid, or as an oil-in-water liquid emulsion.
[0054] As used herein, the term “prodrug” includes entities that have certain protected group(s) and which may not possess pharmacological activity as such, but may, in certain instances, be administered (such as orally or parenterally) and thereafter metabolised in the body to form the agents which are pharmacologically active.
[0055] Furthermore, the invention also provides a kit comprising in combination for simultaneous, separate or sequential use in modulating neoplastic growth, the compound according to formula (I) as defined above or a pharmaceutically acceptable salt, ester or prodrug thereof and an EGFR signalling pathway inhibitor.
DESCRIPTION OF THE FIGURES
[0056] FIG. 1 : shows the average tumour volume (relative to the average volume on the first day of treatment) for A549 (lung carcinoma) xenografts observed for an untreated control group of mice and for mice given (i.e. treated with) Erbitux™ (alone), DMXAA (alone), or a combination of Erbitux™ and DMXAA.
[0057] FIG. 2 : is a representation of the same data used to generate FIG. 1 , but expressed in terms of the percentage of mice having tumour volume less than four times the volume measured on the first day of treatment.
EXAMPLES
Example 1
Method
[0058] Xenografts for human lung cancer are set-up in groups of nude, athymic mice. The cell line selected was A549 (ATCC number CCL-185), a lung carcinoma.
[0059] The A549 was selected as DMXAA has previously been shown to be effective in these cell lines when used in combination with paclitaxel or 5-FU in xenograft studies.
[0000]
Dose level
Group
Cell line
Treatment
(mg/kg)
No. of mice
1
A549
Untreated control
—
10
2
A549
DMXAA
21
10
3
A549
Erbitux ™
33*
10
4
A549
Erbitux ™/DMXAA
33* & 21
10
*Calculated from dose of 1 mg/mouse.
[0060] For this study, DMXAA is given twice in each of Weeks 1 and 4 of the study. Erbitux™ is given twice weekly for four weeks.
[0061] Xenografts are measured two or three times per week and their absolute volume recorded; xenograft tumour volume relative to that recorded on Day 0 (V 0 ) is then calculated. The time taken to reach a relative tumour volume of 3×V 0 is used as a surrogate marker for survival.
Results
[0062] Tables 1 and 2 below, as well as FIGS. 1 and 2 show that the combination of Erbitux™ and DMXAA provides an unexpected synergistic effect in delaying tumour growth.
[0000]
TABLE 1
Results of studies with A549 xenografts.
Dose
Regression
(mg/kg by
Drug
Median VQT
Tumour Growth
Duration b
TTP c
Group
injection)
deaths
(Range; days)
Delay a (Days)
(Days)
(Days)
Erbitux ™
33 d
0/10
44
12
0
4
DMXAA
21
2/10
48
16
0
16
Erbitux ™/
33 d + 21
1/10
70
38
28
34
DMXAA
a The difference in days for treated versus control tumours to quadruple in volume (control tumours quadrupled in 17 (14-23) days).
b Tumour regression duration is the number of days that the tumour volume is less than the original treatment volume.
c TTP: Median time to disease progression.
d Calculated from dose of 1 mg/mouse.
[0000]
TABLE 2
Results of studies with A549 xenografts.
Dose
(mg/kg by
Response e
Group
injection)
PD
PR
SD
CR
Erbitux ™
33 d
0/10
44
12
0
DMXAA
21
2/10
48
16
0
Erbitux ™/
33 d + 21
1/10
70
38
28
DMXAA
d Calculated from dose of 1 mg/mouse.
e PD: Progressive Disease (≧50% increase in tumour size)
PR: Partial Response (≧50% reduction in tumour size sustained over two weeks)
SD: Stable Disease (does not satisfy criteria for PR or PD)
CR: Complete Response (cure; undetectable tumour over two weeks)
ABBREVIATIONS
[0063] AUC=area under curve (plasma concentration vs. time)
CR=Complete Response
[0064] DMXAA=5,6-dimethylxanthenoneacetic acid
EGF=endothelial growth factor
EGFR=endothelial growth factor receptor
ENL=erythema nodosum leprosum
5-FU=5-fluorouracil
HPC=hydroxypropylcellulose
HPMC=hydroxymethylcellulose
ICAM=intracellular adhesion molecule
i.p.=intraperitoneal
MRI=magnetic resonance imaging
PD=Progressive Disease
[0065] PK=pharmacokinetics
PR=Partial Response
SD=Stable Disease
[0066] TTP=median time to disease progression
VDA=vascular disrupting agent
VQT=(tumour) volume quadrupling time | The present invention relates to combinations of the xanthenone acetic acids class such as 5,6-dimethylxanthenone-4-acetic acid (DMXAA) and EGFR signalling pathway inhibitors. More particularly, the invention is concerned with the use of such combinations in the treatment of cancer and pharmaceutical compositions containing such combinations. | 0 |
RELATED APPLICATIONS
This application claims priority to Provisional Application No. 60/460,183, filed Apr. 3, 2003, the entirety of which is hereby incorporated by reference.
This application is also related to the following patents and pending applications, each of which is hereby incorporated herein by reference in its entirety:
U.S. Pat. No. 6,418,478, titled PIPELINED HIGH SPEED DATA TRANSFER MECHANISM, issued Jul. 9, 2002, Application Ser. No. 09/610,738, titled MODULAR BACKUP AND RETRIEVAL SYSTEM USED IN CONJUNCTION WITH A STORAGE AREA NETWORK, filed Jul. 6, 2000, Application Ser. No. 09/744,268, titled LOGICAL VIEW AND ACCESS TO PHYSICAL STORAGE IN MODULAR DATA AND STORAGE MANAGEMENT SYSTEM, filed Jan. 30, 2001, Application Ser. No. 60/409,183, titled DYNAMIC STORAGE DEVICE POOLING IN A COMPUTER SYSTEM, filed Sep. 9, 2002, Application Ser. No. 60/460,234, titled SYSTEM AND METHOD FOR PERFORMING STORAGE OPERATIONS IN A STORAGE NETWORK, filed Apr. 4, 2003,
COPYRIGHT NOTICE
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosures, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND OF THE INVENTION
The invention disclosed herein relates generally to performing storage operations through a firewall. More particularly, the present invention relates to providing a limited number of ports in a firewall for performing secure storage operations between components in a computer network.
Firewalls reside between components in a computer network and generally function to prevent unauthorized access to the network by evaluating which communications should be allowed to pass between the firewall's network and other networks or network components. A firewall thus divides a network into two parts: a friendly/secure side and a hostile side, wherein computers inside the firewall on the friendly side are protected from computers outside the firewall on the hostile side.
A firewall evaluates whether network traffic such as data streams, control messages, application data, communications packets, and other data meets specified security criteria and should be allowed to pass between components of the network. Data that does not meet the security criteria is generally discarded or otherwise blocked from passing between components. A firewall may comprise hardware elements, software components, or any combination thereof. Exemplary firewalls include packet filters, bastion hosts, application or circuit-level gateways, and proxy servers.
One method used by firewalls to prevent unauthorized communications is to restrict network communications to specified ports. A port is generally used by TCP/IP. UDP, and other communication protocols to represent the logical endpoint of a particular connection. For example, HTTP traffic associated with a particular computer might be routed through port 80 . Various programs, services, and other applications on a computer often run listening processes for network traffic directed to a particular port. Limiting network communications to specific ports and closing all unused ports generally reduces the risk of unauthorized access to a computer since these programs, services, and other applications could be compromised or otherwise exploited by a hacker to gain access to the computer.
Firewalls provide additional security by timing out network sessions beyond a specified time period. Thus, ports do not remain unnecessarily open in the event of network connection failures, slowdowns, or other events which might create vulnerabilities. For example, any network sessions that become idle beyond a preconfigured timeout period are automatically disconnected without warning. Further, after making a new connection, a first packet must be sent within a timeout period or the connection is also disconnected.
Existing storage management systems, however, use many thousands of ports to conduct storage operations through a firewall. Typically, these systems keep large sets of known ports open during backups and restores. Each of the streams of data sent as part of a backup, a restore, or other storage operation must have a port open in the firewall to pass the data. For example, data pieces come through multiple streams, control signals come through other streams, status messages come yet other streams, etc. The head end (sender) and tail end (receiver) of existing systems, however, do not know which ports all of the data is coming through, so they generally reserve large blocks of ports in the firewall to accommodate the various streams of data that they anticipate. Furthermore, these systems also must keep many ports open since slow network connections and other factors may cause a connection to timeout and the firewall to close an intended port thus requiring data to be resent to another port. Opening thousands of ports in this manner, however, renders a firewall more like a switch than a firewall and severely compromises network security.
There is thus a need for systems and methods which reduce the number of open ports required in a firewall to perform storage operations in a computer network.
SUMMARY OF THE INVENTION
In some embodiments, the present invention provides systems and methods for performing storage operations through a firewall.
In one embodiment, the invention provides a method for performing storage operations through a firewall in a networked computer system, including identifying, based on configuration data, whether each of a set of network elements is within a trusted network or not within the trusted network. Traffic between elements within the trusted network and elements not within the trusted network must pass through the firewall. The method further includes, prior to performing a storage operation through the firewall, allocating a specific set of ports, in accordance with at least one security parameter, for use in performing the storage operation.
In another embodiment, the invention provides a method for performing storage operations through a firewall in a networked computer system, including identifying, based on configuration data, a first set of network elements which are within a trusted network and a second set of network elements which are not within the trusted network. Traffic between elements within the trusted network and elements not within the trusted network must pass through the firewall. The invention further includes, prior to performing a storage operation through the firewall, allocating a specific set of ports, according to at least one security parameter, for use in performing the storage operation. The method further includes, during the storage operation, monitoring traffic through each of the specific ports. The method further includes, if, through the monitoring, traffic is determined to be inactive through a first port of the specific ports for a specified time period, sending a packet through the first port.
In another embodiment, the invention provides a system for performing storage operations through a firewall in a networked computer system. The system includes a firewall and a plurality of network elements, including one or more client computers and one or more storage devices. The system further includes a storage manager. The system further includes one or more media agents which conduct data between the one or more client computers and the one or more storage devices under the direction of the storage manager. The storage manager identifies, based on configuration data, a first set of network elements which are within a trusted network and a second set of network elements which are not within the trusted network. Traffic between elements of the trusted network and elements not within the trusted network must pass through the firewall. Further, the storage manager, prior to performing a storage operation through the firewall, allocates a specific set of ports, according to at least one security parameter, for use in performing the storage operation. During a storage operation, the firewall opens ports in accordance with the allocation.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated in the figures of the accompanying drawings which are meant to be exemplary and not limiting, in which like references are intended to refer to like or corresponding parts, and in which:
FIG. 1 is a block diagram of a network architecture for a system to perform storage operations through a firewall according to an embodiment of the invention; and
FIG. 2 is a flow diagram of a method of performing storage operations through a firewall according to an embodiment of the invention.
DETAILED DESCRIPTION
With reference to FIG. 1 embodiments of the invention are presented. FIG. 1 presents a block diagram of a network architecture for a system to perform storage operations on electronic data in a computer network according to an embodiment of the invention. As shown, the system includes a storage manager 115 and one or more of the following: a data agent 100 , a client 105 , an information store 110 , an index cache 120 , a firewall 125 , a media agent 130 , and a storage device 135 . The system and elements thereof are exemplary of a three-tier backup system such as the CommVault Galaxy backup system, available from CommVault Systems, Inc. of Oceanport, N.J., and further described in application Ser. No. 09/610,738 which is incorporated herein by reference in its entirety.
A data agent 100 is generally a software module that is generally responsible for archiving, migrating, and recovering data of a client computer 105 stored in an information store 110 or other memory location. Each client computer 105 has at least one data agent 100 and the system can support many client computers 107 . The system provides a plurality of data agents 100 each of which is intended to backup, migrate, and recover data associated with a different application. For example, different individual data agents 100 may be designed to handle Microsoft Exchange data, Lotus Notes data, Microsoft Windows 2000 file system data, Microsoft Active Directory Objects data, and other types of data known in the art.
If a client computer 105 has two or more types of data, one data agent 100 is generally required for each data type to archive, migrate, and restore the client computer 105 data. For example, to backup, migrate, and restore all of the data on a Microsoft Exchange 2000 server, the client computer 105 would use one Microsoft Exchange 2000 Mailbox data agent 100 to backup the Exchange 2000 mailboxes, one Microsoft Exchange 2000 Database data agent 100 to backup the Exchange 2000 databases, one Microsoft Exchange 2000 Public Folder data agent 100 to backup the Exchange 2000 Public Folders, and one Microsoft Windows 2000 File System data agent 100 to backup the client computer's 105 file system. These data agents 100 would be treated as four separate data agents 100 by the system even though they reside on the same client computer 105 .
The storage manager 115 is generally a software module or application that coordinates and controls the system. The storage manager 115 communicates with all elements of the system including data agents 100 , client computers 105 , firewalls 125 , media agents 130 , and storage devices 135 , to initiate and manage system backups, migrations, and recoveries, as well as perform other storage-related operations.
A media agent 130 is generally a media management software module that conducts data, as directed by the storage manager 115 , between the client computer 105 and one or more storage devices 135 such as a tape library, a magnetic media storage device, an optical media storage device, or other storage device. The media agent 130 is communicatively coupled with and controls the storage device 135 . For example, the media agent 130 might instruct the storage device 135 to use a robotic arm or other means to load or eject a media cartridge, and to archive, migrate, or restore application specific data. The media agent 130 generally communicates with the storage device 135 via a local bus such as a SCSI adaptor. In some embodiments, the storage device 135 is communicatively coupled to the data agent 130 via a Storage Area Network (“SAN”).
Each media agent 130 maintain an index cache 120 which generally stores index data the system generates during backup, migration, and restore storage operations as further described herein. For example, storage operations for Microsoft Exchange data generate index data such as file names, file locations, media identifiers, and other information. Index data provides the system with an efficient mechanism for locating user files for recovery operations. This index data is generally stored with the data backed up to the storage device 135 , and the media agent 130 that controls the storage operation also writes an additional copy of the index data to its index cache 120 . The data in the media agent 130 index cache 120 is thus readily available to the system for use in storage operations and other activities without having to be first retrieved from the storage device 135 .
The storage manager 115 also maintains an index cache 120 . Index data is also used to indicate logical associations between components of the system, user preferences, management tasks, network pathways, data associations, storage policies, user preferences, and other useful data. For example, the storage manager 115 might use its index cache 120 to track logical associations between media agents 130 and storage devices 135 .
Index caches 120 typically reside on their corresponding storage component's hard disk or other fixed storage device. Like any cache, the index cache 120 has finite capacity and the amount of index data that can be maintained directly corresponds to the size of that portion of the disk that is allocated to the index cache 120 . In one embodiment, the system manages the index cache 120 on a least recently used (“LRU”) basis as known in the art. When the capacity of the index cache 120 is reached, the system overwrites those files in the index cache 120 that have been least recently accessed with the new index data. In some embodiments, before data in the index cache 120 is overwritten, the data is copied to an index cache 120 copy in a storage device 135 . If a recovery operation requires data that is no longer stored in the index cache 120 , such as in the case of a cache miss, the system recovers the index data from the index cache 120 copy stored in the storage device 135 .
As previously discussed, firewalls 125 reside between components of the system and generally function to prevent unauthorized access to the system. Thus, for example, a firewall 125 may reside between a client 105 and the storage manager 125 , between the storage manager 125 and a media agent 130 , or between other system components. For example, a remote client 105 across the Internet or other wide area network may pass traffic associated with storage operations and other operations to the system via a firewall 125 . As another example, the system may perform remote storage operations, such as remote disaster recovery operations or other operations, and pass traffic associated with storage operations from the storage manager 125 across the Internet or other wide area network to a remote media agent 130 . These examples are not intended to be limiting and other useful configurations will be readily apparent to those skilled in the art.
In some embodiments, components of the system may reside and execute on the same computer. In some embodiments, a client computer 105 component such as a data agent 100 , a media agent 130 , or a storage manager 115 coordinates and directs local archiving, migration, and retrieval application functions as further described in application Ser. No. 09/610,738. This client computer 105 component can function independently or together with other similar client computer 105 components.
The system increases security of storage operations through a firewall 125 by, among other things, drastically reducing the number of ports required as compared to existing storage management systems. The system negotiates a limited number of ports in advance, so that only certain pre-established ports need be open to storage operation traffic. The system also provides a built-in timeout value which is less than the firewall 125 timeout value to eliminate firewall 125 timeouts requiring further renegotiation to open another port.
A port configuration file specifying the ports to open for each system computer is stored in the index cache 120 or other memory of each machine. In some embodiments, the storage manager 115 index cache 120 also contains a master list of all open ports for all computers in the system which can be accessed by and distributed to other machines in the system as necessary. For example, a port configuration file may specify that only ports 8600 to ports 8620 should be opened for use by the system. System hardware and software modules will thus only listen to those ports and all other available ports will remain closed unless requested by some other application, service, process, etc.
The system reserves and also limits the number of ports used by each system component such as the storage manager 115 , data agents 100 , and media agents 130 . In one embodiment, port limitations are based on the minimal number of ports required to conduct storage operations.
For example, the storage manager 115 is allocated seven ports. Three ports carry control data such as start and stop messages, control checksums, parity blocks, and other control data. Three additional ports serve as reserve ports and may be used to support traffic overflow or additional control signals. The final port is used to conduct traffic associated with a graphical user interface (“GUI”). For example, in some embodiments, users at client computers 105 can remotely access the storage manager 115 control GUI and other GUI interfaces. The final port is used to carry signals associated with remote access to the GUI. As another example, the final port also carries signals associated with a user at the storage manager 115 remotely accessing GUIs at clients 115 and media agents 130 . Media agents 115 and data agents 100 are allocated two ports each: one port sends data upstream from the component to the storage manager 115 and one port receives data sent downstream from the storage manager 115 to the component. In some embodiments, media agents 115 and data agents 100 are allocated two additional ports to communicate upstream and downstream with other media agents 115 or data agents 100 . Additional pairs of ports can be allocated to media agents 115 and data agents 100 to provide increased bandwidth, such as for additional backup streams or restore streams.
A “hostile computer” configuration file specifying a list of “hostile” computers is also stored in the index cache 120 or other memory of each machine. In some embodiments, the storage manager 115 index cache 120 also contains a master list of all “hostile” computers in the system which can be accessed by and distributed to other machines in the system as necessary. In some embodiments, a “friendly computer” configuration file specifying a list of “friendly computers is used instead of or concurrently with a “hostile computer” configuration file.
This second configuration file enables, among other thing, the system to determine which computers should pass traffic through the listed firewall 125 ports in the port configuration file and which computers are exempt from passing traffic through the firewall 125 . For example, computers behind the firewall 125 can pass traffic through any ports since they are within the “trusted” network and thus their network traffic does not need to be evaluated by the firewall 125 . Conversely, when one computer is behind the firewall 125 and one computer is not, then traffic between those computers must pass through the firewall 125 via the ports specified in the ports configuration file.
According to one embodiment of the invention, the “hostile computer” configuration file specifying the list of “hostile” computers lists all computers which are on the other side or “hostile” side of the firewall 125 from the computer on which the second configuration file is stored. Traffic with computers not on the list (e.g.—“friendly” computers) is routed directly, however, traffic with computers on the list (e.g.—“hostile” computers) is routed through the firewall 125 . Thus if the storage manager 115 and a media agent 130 are on the “friendly” side of the firewall 125 and a data agent 100 is on the “hostile” side, the storage manager 125 and the media agent 130 configuration files would each list the data agent 100 , and the data agent 100 configuration file would list both the storage manager 125 and the media agent 130 . Computers identified on the second configuration file list are identified according to a network address, an IP address, a DNS entry, a UNC pathway, or other network identifier known in the art.
At startup, system components, such as data agents 100 , data agents 130 , and the storage manager 115 access their ports configuration files and the “hostile computer” configuration files. Data is thus routed through ports in the firewall 125 as appropriate and according to security parameters set forth in the configuration files.
The system also stores a “keep alive” value or key in the index cache 120 or other memory of each machine. The “keep alive” value is generally a value that is less than the connection timeout value specified in the firewall 125 configuration files. The system uses the “keep alive” value, among other things, to prevent the firewall 125 from timing out connections or otherwise closing ports due to network connection failures, slowdowns, or other events which might create vulnerabilities. The system tracks the time period that a connection between a system component, as a data agent 100 , and a firewall 125 has remained idle. If the connection remains idle for a period of time equal or greater than the “keep alive” value, then the system sends a “dummy” packet or other similar packet to the firewall 125 to refresh the connection and restart the timer on the firewall connection timeout value.
In some embodiments, it may be necessary or desirable that chunk creation time be less than a firewall time-out interval, to prevent firewall time-out from occurring. Therefore, if chunk creation time is greater than the firewall time-out interval, then chunk size may be reduced, such as by the storage manager, as necessary to reduce chunk creation time to less than that of the firewall time-out interval.
FIG. 2 presents a flow diagram of a method of performing storage operations through a firewall according to an embodiment of the invention. The system accesses configuration data, step 200 . For example, in some embodiments, the system loads a configuration file specifying system components as hostile or trusted. The system checks the status of a component, step 205 . If a system component is trusted, then traffic is permitted without having to pass through the firewall, step 210 . For example, trusted components inside the firewall may not be required to pass traffic through the firewall. If a component is not trusted, the system allocates one or more specified ports to that component according to security preferences, step 215 . The system monitors ports allocated to components, step 220 , and determines whether a time period, for example a firewall timeout setting, has been exceeded, step 225 . In some embodiments, the system monitors to determine whether traffic has passed through an allocated port within the time period. If the time period has not been exceeded, control returns to step 220 and the system continues to monitor traffic. Otherwise, if the time period has been exceeded, the system sends a packet, such as a dummy packet to prevent a port closing, through the port, step 230 , and control returns to step 220 .
Systems and modules described herein may comprise software, firmware, hardware, or any combination(s) of software, firmware, or hardware suitable for the purposes described herein. Software and other modules may reside on servers, workstations, personal computers, computerized tablets, PDAs, and other devices suitable for the purposes described herein. Software and other modules may be accessible via local memory, via a network, via a browser or other application in an ASP context, or via other means suitable for the purposes described herein. Data structures described herein may comprise computer files, variables, programming arrays, programming structures, or any electronic information storage schemes or methods, or any combinations thereof, suitable for the purposes described herein. User interface elements described herein may comprise elements from graphical user interfaces, command line interfaces, and other interfaces suitable for the purposes described herein. Screenshots presented and described herein can be displayed differently as known in the art to input, access, change, manipulate, modify, alter, and work with information.
While the invention has been described and illustrated in connection with preferred embodiments, many variations and modifications as will be evident to those skilled in this art may be made without departing from the spirit and scope of the invention, and the invention is thus not to be limited to the precise details of methodology or construction set forth above as such variations and modification are intended to be included within the scope of the invention. | The present invention provides systems and methods for performing storage operations through a firewall. Methods are provided that include, in a networked computer system, identifying, based on configuration data, whether each of a set of network elements is within a trusted network or not within the trusted network. Traffic between elements within the trusted network and elements not within the trusted network must pass through a firewall. The methods also include, prior to performing a storage operation through the firewall, allocating a specific set of ports, in accordance with at least one security parameter, for use in performing the storage operation. Methods are also provided which include monitoring traffic through the specific ports, and, if traffic is determined to be inactive through a first port of the specific ports, sending a packet through the first port. | 7 |
This application is a continuation of U.S. application Ser. No. 4,366, filed Jan. 16, 1987, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to apparatuses for handling sheet-like articles, and more particularly, to apparatuses for stacking envelopes into stacks of a predetermined number, packing the stacks into cartons, sealing the cartons and transporting the sealed cartons to an area for loading into shipping containers.
The manufacture of envelopes of the type used to enclose folded documents such as letters, bills, and the like has been automated to the point wherein a single apparatus receives a web unwound from a roll of paper, cuts the web into planks, imprints, folds, and glues the blanks to form envelopes, and arranges the folded and glued envelopes at a discharge station in a horizontal column. An example of such a machine is a rotary reel-fed envelope machine manufactured by Winkler & Dunnebier. Once the envelopes are manufactured by such a machine, they must be separated into groups of a predetermined number, such as 50 or 100 envelopes, loaded into set-up cartons, and the cartons loaded into shipping containers. There also exist devices for separating the envelopes in the horizontal column into groups.
However, presently the groups of envelopes must be manually removed from a horizontal column formed by the envelope machine and placed into the open tops of set-up cartons. The cartons are then transported to a sealing machine and the cartons discharged from the sealing machine must be manually loaded into shipping containers.
In view of the unavoidable hazards present with the manual loading of envelopes into a set-up carton due to the properties of the paper forming the envelopes, and the chance for error resulting from the repeated performance of a manual task, it is desirable to automate this portion of the envelope handling system as well. Suggestions for such automation may be found in several patents.
For example, the Yamada et al. U.S. Pat. No. 4,511,136 discloses a sheet handling device in which a spider feeder feeds sheets traveling horizontally from an upper level conveyor and deposits them into a vertical stack on a lower level conveyor. The apparatus includes reciprocating fingers which are projectable into and out of a sheet stacking zone so that sheets may be collected above the lower level conveyor in order to provide sufficient time for the lower level conveyor to index a completed stack away from the stacking zone. A disadvantage with such a device is that it is incapable of handling freshly folded envelopes which contain air and must be compressed to a height which approximates the thickness of the carton into which they will be packed.
A device for compressing stacks is disclosed in the Sasaki et al U.S. Pat. No. 4,339,119. That patent discloses a sheet stacking apparatus in which reciprocating rods are projected into a stacking zone to catch sheets discharged by an upper level conveyor and accumulate the sheets into a stack. The apparatus includes a "beat member" which presses against the sheets and compresses them against the rods.
A disadvantage with the device disclosed in the Sasaki et al. patent is that it cannot be used with a spider feeder mechanism such as that shown in the Yamada et al. patent. A spider feeder mechanism is an important component in any such system since it provides a mechanism for receiving envelopes or other sheet-like articles from a high level conveyor and depositing them into a vertical stack at a lower level without permitting the envelopes or articles to tumble.
In order to automate that portion of the system in which stacks of articles are packed into set-up cartons, it is necessary to provide a mechanism which removes the articles from a conveyor and feeds them into the carton. Such a device is suggested in the Lister et al. U.S. Pat. No. 4,06,169. That patent discloses an apparatus for packing semi-compressable articles, such as towels, into preformed plastic bags open at one end. The apparatus includes a conveyor which transports the stack of towels to a reciprocating ram which, in turn, transports the stack sidewardly through a pair of gate members and into the preformed bag. The gate members include converging top and side walls for compressing and guiding the stack as it enters the bag.
A disadvantage of such a device is that it cannot be used with other automated equipment of the type which automatically sets up a carton and, subsequent to the carton being loaded with articles, transports the carton to a sealing device. In contrast, the Lister et al. apparatus requires that bags manually be placed in registry with the gate members and, after loading, be manually removed from engagement with the gate members.
Accordingly, there is a need for a system for receiving folded and glued envelopes from a reel-fed envelope machine, stacking the envelopes into vertical stacks into a bucket conveyor, packing the stacks of envelopes into set-up cartons, sealing the cartons, and transporting the sealed cartons to an area for loading in shipping containers. Such a system should be as fully automated at possible and preferably should be capable of use with currently available machines.
SUMMARY OF THE INVENTION
The present invention is a system for receiving envelopes from an envelope machine, arranging the envelopes in vertical stacks of a predetermined number, packing the stacks into set-up cartons, sealing the cartons, and transporting the cartons to an area for loading into a shipping container. The system is fully automated so that manual steps are not required until the cartons are placed into the shipping container.
The system includes a sheet stacking component having a spider feeder for receiving envelopes from the envelope machine and releasing them to fall in a vertical direction into a stacking zone, a pair of pivoting hold back fingers projectable into the stacking zone for interrupting a flow of articles from the blade wheel feeder, a pair of pivoting transfer fingers projectable into the stacking zone below the blade wheel feeder for compressing the height of a completed stack, and pivoting bottom fingers which are capable of moving upwardly to receive the initial sheets of the stack and then pivoting downwardly as the stack grows in height, eventually to the stack onto a bucket conveyor.
Both the hold back fingers and the bottom fingers are counterweighted so that initially they pivot upwardly to receive sheets, then gradually pivot downwardly as the stacks they support grows in size and weight. In contrast, the transfer fingers are pivoted by a double-acting cylinder motor so that they are capable of urging a completed stack supported on the bottom fingers downwardly to place that stack onto a bucket conveyor and, at the same time, compress the stack.
The stacking apparatus also includes a misfeed detector which is positioned above the associated bucket conveyor and slightly downstream of the stacking zone. The misfeed detector includes a pair of L-shaped members attached to a transverse axle pivotally supported on a frame attached to the conveyor. Should a stack be misfed onto a bucket, the resulting increase in height will cause the stack to contact one or both of the L-shaped members causing the axle to pivot and trip a sensor which sends a signal to a control to stop the loading operation.
In operation, the spider feeder initially deposits envelopes into a first vertical stack upon the bottom fingers which have been pivoted upwardly by the counterweight. After a predetermined number of envelopes have collected on the bottom fingers, the hold back fingers project into the stacking zone and interrupt the flow of envelopes to the bottom fingers so that envelopes begin collecting upon the hold back fingers in a second stack. At the same time, the transfer fingers project into the stacking zone below the hold back fingers and are urged downwardly to lower the first stack onto a bucket conveyor. The conveyor indexes forwardly to remove the loaded bucket from the stacking zone and replace it with an empty bucket for the second stack.
At this time, the double-acting cylinder motor pivots the transfer fingers upwardly, allowing the bottom fingers to pivot upwardly in response to the counterweight, and the transfer and hold back fingers retract from the stacking zone allowing the partially collected second stack to fall upon the bottom fingers, and the cycle begins again. The advantage of this component of the system is that it receives envelopes from an envelope machine in a continuous manner, collects them into discrete, vertical stacks, partially compresses the stacks, and loads the stacks onto a bucket conveyor, all without interrupting the continuous operation of the envelope machine.
The envelope packing component of the system includes a ram for displacing a stack of envelopes from the conveyor toward a set-up carton in a packing zone, a chute for conveying a stack from the bucket, and a pair of gate members for conveying the stack from the chute to the interior of the carton. The ram is connected to a double-acting cylinder motor and the gate members are pivoted by rotary actuators between a loading or open position, in which they extend into the carton interior, and a closed position. The walls of the chute and gate members converge so that a stack is compressed and aligned as it passes from the conveyor to the set-up carton.
The cartons are set-up by a carton machine of known design which also includes a sealing component that folds the end flaps of the cartons, seals the cartons and discharges the sealed cartons to be conveyed to the carton packing area. The carton machine includes front and rear tucker bars which have been modified to maintain the bottom panel end flaps of a loaded carton closed prior to the time the carton enters the sealing apparatus, without deflecting the top panel end flaps of the carton. The rear tucker bar is actuated first so that it provides a backstop for preventing the envelopes from protruding from the opposite, open end of the carton. The front tucker bar is actuated after the ram is withdrawn from the carton to close the front bottom panel end flap of the carton.
At the beginning of the operation sequence for the envelope packing apparatus, the carton machine sets up a folded carton blank in a packing zone so that its front open end is in registry with the gate members, and the gate members pivot to a packing configuration in which their outer ends extend within the interior of the carton. The ram then displaces a stack sidewardly from a bucket on the conveyor through the chute, the pivoted gate members, and into the interior of the set-up carton. The ram withdraws from the carton and, as it clears the gate members, the gate members pivot to a position in which the members are withdrawn from the carton interior and are aligned parallel to the direction of travel of the carton. The front tucker closes the bottom panel end flap, and the packed carton is transported from the packing zone to the sealing machine.
Another component of the system is a carton transporting apparatus which is designed to be used in combination with a sealing apparatus of the type having a top discharge in which the packed cartons are lying on a side panel. The transporting apparatus includes a helical channel which receives the cartons from the sealing apparatus and rotates the cartons to an upright position. A reciprocating plate positioned above the sealing apparatus urges cartons emerging from the sealing apparatus along the helical channel.
The terminal portion of the channel is supported in a horizontal surface, such as work table, and includes a reciprocating platen. The reciprocating platen urges the cartons deposited on the table in a direction perpendicular to the direction of travel along the channel so that the cartons form a horizontal column in which side pannels of the cartons abut.
In a preferred embodiment, the helical channel includes a raised portion adjacent to the terminal portion of the channel which contacts the bottom panels of the cartons and prevents more than a single carton from being deposited upon the horizontal table at a time.
A specific carton has been designed for use with this envelope handling system. This carton includes a full bottom panel, front and rear side panels, and two partially-overlapping partial top panels connected to the side panels at score lines. Only one of the partial top panels is provided with a pair of opposing end flaps; the other partial top panel is "flapless."
In this configuration, gaps are formed between the end flaps of the partial top panel and the end flaps of the side panel adjacent to the flapless partial top panel When used in the carton handling appartus comprising the envelope packing component of the envelope handling system, the carton is set up such that the top panels face downstream towards the sealing apparatus. When the tucker bars are actuated, they are able to contact and close the upstream bottom panel end flaps, extend across the open ends of the carton, through the gaps below the top panel end flaps, and terminate beyond the top panel of the carton.
This allows the ends of the cartons to be completely closed to prevent envelopes within the interior from escaping, and forms a continuous guide which abuts the flap closing rails of the sealing apparatus so that the likelihood of the bottom panel end flaps opening prior to the carton entering the sealing apparatus is minimized.
Another aspect of the carton is that it is designed so that the envelopes are accessible to a user from both and end of the carton and the top. The partial end flaps are attached to the associated partial top panels by score lines which include perforations which facilitate separation of the flaps from the panel. Accordingly, the top of the set-up carton may be opened by separating the partial panels from each other, then separating the partial top panel from each other, then separating the inner partial top panel from its respective side panels. To make this top opening resealable, the outer partial top panel is provided with a tab and the inner partial top panel is provided with a slit shaped to receive the tab.
Accordingly, it is an object of the present invention to provide an envelope handling system in which envelopes are removed from a high level conveyor and released to fall into a vertical stack with a minimum of tumbling; an envelope handling system in which envelopes are taken from a continuously operating envelope machine and stacked in stacks of predetermined sized on a bucket conveyor without interrupting the operation of the envelope machine; an envelope handling system which automatically removes stacks of envelopes from a bucket conveyor and packs the stacks into set-up cartons; an envelope handling system in which sealed cartons are transported to a loading area and arranged in a horizontal column to facilitate packing in shipping containers; a carton for use with an envelope handling system which facilitates the use of flap closing components; and an envelope handling system in which the number of manual operations required to stack envelopes, place the envelopes in cartons, and load the cartons in shipping containers is minimized.
Other objects and advantages of the present invention will be apparent from the following description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic, perspective view of a preferred embodiment of the envelope handling system of the present invention;
FIG. 2 is an exploded, perspective view of the envelope stacking component of the system of FIG. 1;
FIG. 3 is a perspective, partially exploded view of a detail of the stacking component of FIG. 2, showing the hold fingers, transfer fingers, and bottom fingers;
FIG. 4 is a detail showing the double-acting cylinder motor for actuating the transfer fingers shown in FIG. 3;
FIGS. 5, 6, 7, and 8 each are schematic side elevations of the sheet stacking component shown in FIG. 2, and progressively show the continuous removal of envelopes from the spider feeder and the loading of the envelopes onto an associated bucket conveyor;
FIGS. 9, 10, 11 and 12 are each details showing, in perspective, the envelope packing component of the system of FIG. 1, and show, in sequence, the operation of packing a stack of envelopes into a set-up carton;
FIG. 13 is a perspective view showing the carton conveying component of FIG. 1;
FIG. 1 is a diagram of the computer control of the embodiment of FIG. 1;
FIG. 15 is a top plan view of a box blank used to form a carton of the type shown in FIG. 1;
FIGS. 16, 17, 18, and 19 together show the sequence in which the end flaps of the carton of FIG. 1 are folded; and
FIG. 20 is a perspective view of an intermediate folded blank of, the carton shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, the envelope handling system of the present invention includes a sheet stacking component, generally designated 30, an envelope packing component 32, and a carton transporting apparatus 34. An endless bucket conveyor, generally designated 36, extends between the sheet stacking component 30 and the envelope packing apparatus 32.
The conveyor 36 includes a flexible belt 38 which supports a plurality of individual buckets 40. Each bucket 40 includes front and rear pairs of legs 42, 44, and a central, U-shaped channel 46 for supporting a stack 48 of envelopes 50.
Sheet Stacking Apparatus
As shown in FIGS. 1, 2, and 3, the sheet stacking component includes a spider feeder, generally designated 52, hold back fingers 54, transfer fingers 56, and bottom fingers 58. The spider feeder 52 comprises three disks 60, 62, 64 which are spaced from each other and mounted on a common axle 66. Each of the disks 60-64 includes a plurality of arcuate, tapering arms 68 spaced about its periphery and separated from each other to form slots 70 shaped to receive envelopes 50.
The spider feeder 52 is positioned to receive envelopes from the output conveyor of an envelope machine (not shown). A typical machine which may be used with the system of the present invention is a Helios 399 G/GS rotary reel-fed envelope machine, manufactured by Winkler & Dunnebier, GmbH & Co. KG, Neuwied, West Germany.
The hold back fingers 54, transfer fingers 56 and bottom fingers 58 are positioned below and rearwardly of the spider feeder 52. As shown in FIGS. 2 and 3, the hold back fingers 54 include a U-shaped mounting bracket 72, a forwardly extending strut 74, and a pair of mounting channels 76, 78 attached to opposite sides of the strut. The strut 74 includes a boss 80 at its base adjacent to the bracket 72, and the boss receives a mounting block 82. Left and right double-acting cylinder motors 84, 86, respectively, are attached to the mounting block 82 and includes rods 88, 90 attached to slide blocks 92, 94.
The slide blocks 92, 94 are seated in longitudinal slots 96, 98 formed in the mounting channel 76, 78, respectively, and receive the rearward ends of left and right hold back pins 100, 102. The hold back pins 100, 102 extend through holes formed in forward bearing blocks 104, 106 and are seated, when retracted, within rearward bearing blocks 108, 110, attached to opposite ends of longitudinal channels 96, 98, respectively.
Actuation of the cylinder motors 84, 86 such that the rods 88, 90 extend outwardly causes the slide blocks 92, 94 to travel within the channels 96, 98 and displace the pins 100, 102 outwardly from the mounting channels 76, 78. The longitudinal slots 96, 98 are sized such that displacement of the slide blocks 92, 94 to the rear of the slots causes the rods 100, 102 to retract completely within the mounting channels 76, 78.
The bracket 72 includes journal bearing 111 forming a transverse bore 112 which is journaled onto an axle 114. The axle 114 is attached to a frame 116 which, in turn, is mounted on and extends rearwardly from the conveyor 36. The hold back fingers 54 are centered on the axle by means of a clevis 118 that receives a shaft collar 120 fixed to an axle 114. The clevis 118 includes a transverse passage (not shown) which forms a part of the transverse bore 112 receiving the axle 114.
An adjustable counterweight 122 is mounted on a rod 124 which is attached to a mounting block 126 fastened to the bracket 72 by machine screws 128. The counterweight 122 is adjusted along the rod 124 such that its weight pivots the mounting channels 76, 78 about axle 114 upwardly toward the spider feeder 52.
The transfer fingers 156 include left and right mounting bracktes 130, 132, respectively, which are attached to left and right mounting channels 134, 136. The mounting channels 134, 136 are separated by struts 138, 140 and include longitudinal slots 142, 143.
Double-acting cylinder motors 144, 146 are mounted on the mounting brackets 130, 132, respectively, and include rods 148, 150 attached to the upper portions of slide blocks 152, 154. The slide blocks 152, 154 ride in the longitudinal slots 142, 143 and are attached to transfer pins 156, 158, respectively. The pins 156, 158 are journaled into forward bearing blocks mounted on the forward ends of the channel 134, 136, 160, 162, and, when retracted, engage rearward bearing blocks 164, 166, placed at the rearward ends of the longitudinal slots 142, 143, respectively. The mounting brackets 130, 132 include journal bearings 168, 170 which receive the axle 114.
Mounting channel 146 includes a knuckle 172 which is attached to the clevis 174 of a double-acting cylinder motor 176 The cylinder motor 176 is pivotally attached to a clevis 178 that, in turn, is attached to a downwardly-extending bar 180. The bar 180 is connected to a transverse boss 182 forming and intergral part of the frame 116.
As best shown in FIG. 4, the clevis 174 includes a tubular portion 184 having a pair of longitudinal slots formed therein (only one of which is shown), and an annular shoulder 188. A cylindrical rod 190 telescopes into the tubular member 184 and includes a cross pin 192 which is captured within and slides along the slots 186. The rod 190 terminates at its lower end in a disk-shaped spring seat 194 that includes a mounting nut 196 receiving the end of the cylinder rod 198 of the cylinder motor 176. A coiled spring 200 is captured between the annular shoulder 188 and spring seat 194, which are spaced apart sufficiently to allow the spring to urge the rod 190 out of the tubular member 184 and drive the pin 192 against the bottom of the seat 192.
The bottom fingers 58 include a U-shaped yoke 202 and three finger elements 204, 206, 208. The finger elements 204-208 include rectangular bars 210, 212, 214 which are attached at their bases to the yoke 202 and terminate in finger plates 216, 218, 220, respectively. A crossbar 222 extends transversely of and is attached to the bars 210-214, and includes a resilient boss 224 which is positioned to contact the underside of strut 138 of the transfer fingers 56.
The yoke 202 includes journal bearings 226, 228 which are sized to receive the axle 114, and are carried on upright mounting brackets 230, 232 that are spaced apart sufficiently to receive the transfer fingers therebetween. A counterweight 234 is adjustably mounted on a rod 236 extending rearwardly from the yoke 202. The forward tip of the rod 236 is fixed to a boss 238 mounted on the underside of the finger element 206. The yoke 202 is centered on the axle 114 by shaft collars 240, 242.
The conveyor 36 on which the sheet stacking apparatus is mounted includes a pair of inverted, L-shaped side channels 244, 246 which open inward and face the buckets 40. The stacks 48 of envelopes 50 (see FIG. 1) travel within the channels and are maintained in their compressed configuration by the upper horizontal surfaces 247 of the channels 244, 246 as they are conveyed toward the envelope packing apparatus 32. A pair of separator bars 248, 250 are mounted on the upper surfaces of the side channels 244, 246 and, as will be explained, operate to remove envelopes 50 from the slots 70 of the spider 52. Preferably, the separator bars 248, 250 are arcuate in shape, having as centers of curvature the axle 114.
The conveyor 36 includes a misfeed detector 252 which includes upright members 254, 256 attached to the side channels 244, 246, respectively, which in turn support a transverse axle 258. Attached to the transverse axle are a pair of L-shaped members 260, 262 that include vertical components 264, 266, respectively. Vertical component 266 includes a detent (not shown) which engages a dimple 267 in upright member 256 when the components are aligned with the members. The detent provides a "break away" action for the L-shaped members.
Vertical component 266 includes a trip plate 268 which is positioned adjacent to a proximity switch 270 mounted on the upright member 256. A stack of envelopes indexed forwardly in a bucket 40 which includes envelopes above the side channels 244, 246 will impact the L-shaped members 260, 262 and cause the axle 258 to rotate, removing the trip plate 268 from the immediate vicinity of the proximity switch 270, thereby generating a signal indicating that a jam or a misfeed has occured.
The operation of the sheet stacking apparatus is as follows. As shown in FIG. 5, envelopes 50 are conveyed from an upper level conveyor (not shown) to a stacking zone 272 by the spider feeder 52, where they contact the separator bars 248, 250 and are removed from the spider feeder disks 60, 62, 64 (see FIG. 1). At this time, the hold back pins 100, 102 and transfer pins 156, 158 have been withdrawn within their respective mounting channels 76, 78, 134, 136, and the cylinder motor 176 has been actuated to pivot the transfer fingers 56 to an upward position. This allows the bottom fingers 58 to pivot upwardly as well in response to the force exerted by the counterweight 234.
As the envelopes 50 fall from the spider feeder 52, they collect in a first stack 48 upon the bottom fingers 58. By permitting the bottom fingers 58 to pivot upwardly as shown in FIG. 5, the distance the envelopes 50 fall before collecting into the stack 48 is minimized, thereby minimizing the likelihood of a misaligned stack. The counterweight 234 is adjusted such that the bottom fingers 58 pivot downwardly in response to the increasing weight of the first stack 48 collecting upon it.
As the envelopes 50 slide out of slots 70 of the spider feeder 52, they exert a downward force on the hold back and transfer fingers 54, 56, respectively. Hold back fingers 54 pivot downwardly in response to this force, while the spring-loaded clevis 174 (FIG. 4) allows the transfer fingers 56 to pivot slightly downwardly.
As shown in FIG. 6, when a predetermined number of envelopes 50 have been collected upon the bottom fingers 58, the cylinder motors 84, 86 of the hold back fingers 54 and the cylinder motors 144, 146 of the transfer fingers 56 are actuated to displace their respective pins 100, 102, 156, 158 outwardly (see FIG. 2). Consequently, successive envelopes 50' leaving the spider feeder collect upon the hold back pins 100, 102 of the hold back fingers 54 in a second stack 48'.
As shown in FIG. 7, the cylinder motor 176 is actuated to pivot the transfer fingers 56 downwardly, which causes the transfer pins 156, 158 to bear down against the topmost envelope of the completed first stack 48. This downward force compresses the stack and urges the bottom fingers 58 downwardly to place the stack within the bucket 40 of the conveyor 36. The finger plates 216, 218, 220 (see FIG. 2) are spaced such that the rear legs 44 of the bucket extend between them. Once the stack 48 has been lowered so that it rests upon the channel 46, the conveyor 36 is actuated to index the loaded bucket forwardly, thereby removing that bucket from the bottom fingers 58 in the stacking zone 272 and presenting an empty bucket 40' into the stacking zone, as shown in FIG. 8.
At this time, the cylinder motor 176 is actuated to pivot the transfer fingers 156 upwardly, which allows the bottom fingers 58, now empty, to rise to the position shown in FIG. 5. At that time, all four pins 100, 102, 156, 158 are retracted to allow the stack 50', which had been collecting upon the hold back pins 100, 102, to fall upon the fingers 216, 218, 220 of the bottom fingers 58.
It should be noted that the counterweight 122 of the hold back fingers 54 is adjusted such that the hold back pins 100, 102 are pivoted downwardly under the increasing weight of the collected stack 50'. Consequently, the distance that a released envelope must fall is maintained at a minimum and is consistent for every envelope collected into the stack 50'.
Envelope Packing Apparatus
As shown in FIGS. 1 and 9, the envelope packing apparatus 32 includes a ram 274 consisting of a double-acting cylinder motor 276 having a C-shaped bracket 278 attached to the end of its rod 280. A chute 282 is positioned adjacent to the conveyor 36 opposite the ram 276 and includes converging top, bottom and side walls 284, 286, 288, 290, respectively, which act to compress and align a stack 50 of envelopes passing through it.
A pair of gate members 292, 294 are positioned on a side of the chute 282 opposite the conveyor 36 and are attached to vertical pivot shafts 296, 298 which are positioned by rotary actuators (not shown). The gate members 292, 294, each comprise a L-shaped channel having converging top and bottom walls, and a beveled outer end 299 to provide clearance when the members pivot between the open or packing position shown in FIG. 10, and the closed position of FIG. 9. The gate members 292, 294 are positioned adjacent to a carton machine, generally designated 300. The carton machine 300 is positioned to pull cartons 302 from a magazine 304 of carton blanks 306 and set-up the cartons such that its open end 308 is in registry with the gate members 292, 294. An example of such a carton machine 300 is the Econoseal E-System, manufactured by Econocorp, Inc., Needham Heights, Mass.
The carton machine 300 includes a horizontal ram plate 310 which contacts and sets up the cartons 302, a double-acting cylinder motor 312 for displacing the ram plate in a downstream direction, a series of rails, generally designated 314, for closing the end flaps of the carton 302, and a sealing and cooling component, generally designated 316.
The carton machine 300 has been modified to include front and rear tucker bars 318, 320, which are attached to double-acting cylinder motors 322, 324, respectively. Each of the tucker bars 318, 320 includes a side plate 326 terminating in a rounded finger 328. The fingers 328 of the tucker bars 318, 320 are shaped to extend through gaps 330, 332 formed between the front and rear partial end flaps 334, 336, and the side flaps 338, 340 (see also FIG. 19).
The operation of the envelope packing apparatus is shown sequentially in FIGS. 9, 10, 11 and 12. After the carton machine 300 has set-up a blank 306 in a packing zone 341 (see also FIG. 1) to form a carton 302 with front and rear open ends 308, 342, cylinder motor 324 is actuated to displace rear tucker bar 320 forward, thereby closing rear bottom end flap 334 and blocking the rear open end 342 of the carton. The conveyor 36 is actuated to bring a bucket 40 loaded with a stack 48 of envelopes into registry with the chute 282.
As shown in FIG. 10, gate members 292, 294 are pivoted about shafts 296, 298 such that their forward portions 299 enter the interior 346 of the carton 302, and the gate members are aligned with the chute 282 and are perpendicular to a direction of travel of the carton, indicated by arrow A in FIG. 1.
Cylinder motor 276 of ram 274 is actuated to extend rod 280 so that C-bracket 278 displaces stack 50 from between the front and rear legs 42, 44 of the bucket 40 sidewardly through and gate members 292, 294 , each of which compresses and aligns the stack, and into the interior 346 of the carton 302. The presence of the rear tucker bar 326 prevents the envelopes within the stack 48 from exiting the rear open end 342.
As shown in FIG. 11, the cylinder motor 276 is actuated to withdraw the bracket 278 to a position adjacent to the conveyor 36 opposite the chute 282, which provides clearance for the conveyor to index a next bucket 40 adjacent to the packing zone 341. At this time, the gate members 292, 294 are pivoted out of the interior 346 of the carton 302, thereby providing clearance for the carton to be displaced from the packing zone 341, in a downstream direction relative to the carton machine 300 (FIG. 1).
Rotation of the gate members 292, 294 also provide clearance for the front tucker bar 318 to be indexed forwardly to close the front bottom end flap 348. It should be noted that, at this time, the fingers 328 of the front and rear tucker bars 318, 320 protrude through the gaps 330, 332 present in the carton 302, so that there is a substantially continuous rail formed with the rails 314 of the sealing component 316 (FIG. 1) which prevents the front and rear bottom end flaps 348, 344 from springing open as the carton is displaced from the packing zone 341.
As shown in FIG. 12, the double-acting cylinder motor 312 is actuated to displace the ram plate 310 in a downstream direction from the packing zone 341 toward the sealing component 316, thereby displacing the loaded carton 302 along support rails 350 of the carton machine 300. After the cylinder 312 withdraws the ram plate 310 to its original position shown in FIG. 1, the cycle may begin again.
Carton Transporting Apparatus
As shown in FIGS. 1 and 13, the carton transporting apparatus 34 is used in combination with the carton sealing component 316 which receives loaded cartons at a lower level seals the end flaps of the carton, allows the adhesive to cool, and discharges sealed cartons 302' vertically. The transporting apparatus includes a pushing element 350, a helical channel 352, and a queuing component 354. The pushing element 350 includes a support frame 356, a double-acting cylinder motor 358, a longitudinal rod 360 and a pusher plate 362. The pusher plate includes a mounting bracket 364 which is journaled onto the longitudinal rod and is connected to the rod 366 of the cylinder 358. The pushing element 350 is oriented such that actuation of the cylinder 358 causes the plate 362 to reciprocate in a direction that is aligned with the direction of travel of the channel 352.
The channel 352 includes a helical major wall 368 that is substantially horizontal at an end adjacent to the sealing component 316 and positioned to receive a sealed carton 302', and is substantially vertical adjacent to the queuing component 354. The major wall 368 is attached to a minor wall 370 which is substantially vertical adjacent to the discharge of the sealing component 316, and is substantially horizontal adjacent to the queuing component 354 The minor wall 370 includes an upwardly extending portion 372 which is positioned adjacent to the queuing component 354.
The queuing component 354 includes a double-acting cylinder motor 374 having a rod 376 that is connected to a horizontally-extending platen 378. The platen 378 is positioned within a terminal cut-out 380 formed in the major wall 368. The cylinder 374 is positioned adjacent to a support table 382 which forms a part of a container loading station, generally designated 384 (see FIG. 1). Preferably, the cylinder motor 374 is connected to the pneumatic system of the sealing component 316, as is the cylinder motor 358. Cylinder motors 374, 558 cycle simultaneously.
The operation of the carton transporting apparatus 34 is as follows. Sealed cartons 302' are discharged upwardly from the sealing component 316. As a carton 302' is raised to an elevation corresponding to the horizontal component of the major wall 368, and the double-acting cylinder motor 358 is actuated to draw the cylinder rod 366 inwardly, thereby displacing the pushing plate 362 toward the channel 352. This moves the carton onto the channel 352.
This process is repeated for successive sealed cartons, eventually loading the channel 352 with cartons 302' positioned end-to-end. The cartons are prevented from sliding all at once onto the support table 382 by the upwardly extending portion 372, which is positioned to prevent cartons from sliding freely thereover and allow only a single carton to slide onto the table at one time. As each carton is deposited on the table 382 in front of the queuing component 354, the cylinder motor 374 is actuated to displace the platen 378 outwardly, thereby moving the carton 302' in a direction perpendicular to its direction of travel along the channel 352.
Successive displacement of cartons deposited on the table forms a horizontal column of cartons 302' which are arranged such that their side panels abut each other. The cartons may then be loaded into shipping containers 386.
Computer Control
As shown schematically in FIG. 14, the sheet handling system of the present invention is operated automatically by a computer control 386. In the preferred embodiment, the control is a GE Series I programmable conroller manufactured by General Electric Corporation. As shown in FIGS. 1 and 2, an electric eye 388 is associated with the spider feeder 52 and detects the presence of envelopes 50 within the slots 70. The signals generated by the electric eye enable the control 386 to count the number of envelopes entering the stacking zone 272 (see FIG. 5) to enable the control to actuate the hold back fingers 54 to project into the stacking zone 272 to begin a new stack.
As shown in FIGS. 2 and 3, the mounting channel 136 of the transfer fingers 58 includes a trip-plate 390 which is positioned adjacent to a proximity switch 392 mounted on the frame 116. When the transfer fingers 56 have been lowered by double-acting cylinder 176 to the point where the proximity switch is tripped 40, the control 386 actuates the conveyor 36 to index the bucket, now loaded with a stack 48, forwardly out of the stacking zone 272.
As explained previously, a proximity switch 270 is tripped when a misfeed occures in which a stack of envelopes is lofted such that the L-shaped members 260, 262 are pivoted about the axle 258. This signal causes the control 386 to stop the stacking process.
A photo cell 394 is positioned above the conveyor and slightly outward of it for detecting the presence of a stack 48 adjacent to the double-acting cylinder 276. When a stack 48 actuates the photocell 394, the control 386 actuates the double-acting cylinder 276 to displace the stack through the chute 282 and into the carton 302 (see FIG. 1).
A photocell 396 is positioned above the gate members 292, 294, and detects the return stroke of the double-acting cylinder 276. When photocell 396 is actuated, the control 386 activates the rotary actuators to pivot the gate members 292, 294 to a closed position shown in FIG. 11. Limit switches 398, 400 are mounted internally of the double-acting cylinder motor 276, and signal the control 386 when the rod 280 has reached the limits of its stroke. When the rod 280 is fully extended, the control 386 is signalled to begin the return stroke. When the rod 280 is fully retracted, the control 386 is signalled to index the conveyor 36.
Although the carton machine 300 is of a type known in the art, in the preferred embodiment it has been modified to include a photocell 402 which detects the presence of a set-up carton 302 adjacent to the ram plate 310 (see FIG. 1). The presence of a set-up carton 302 as shown in FIG. 1 signals the control 386 to actuate the ram 274 to displace the stack 48 of envelopes into the set-up carton 302.
Carton
As shown in FIG. 15, the carton used with the envelope handling system previously described is made from a blank 404. Blank 404 includes a bottom panel 406, side panels 408, 410, and inner and outer partial top panels 412, 414 respectively. The side panels 408, 410 are connected to the bottom panel 406 along longitudinal score lines 416, 418, respectively. Partial top panel 412 is connected to side panel 408 at a longitudinal score line 420, and partial top panel 414 is connected to side panel 410 at a longitudinal score line 422 extending alongs its length. Partial top panel 412 includes a slit 424 which is shaped to receive a tab 426 formed in partial top panel 414 when the carton 302 (FIG. 16) is opened and resealed.
Bottom panel 406 includes front and rear end flaps 428, 430 connected at transverse score lines 432, 434, respectively. Side panel 408 includes front and rear end flaps 436, 438 connected by transverse perforated score lines 440, 442, respectively. Side panel 410 includes front and rear end flaps 338, 340 connected by transverse perforated score lines 444, 446, respectivley. In the preferred embodiment, flaps 338, 340 are slightly shorter in length than flaps 436, 438, to provide clearance with side panel 408 when folded as shown in FIG. 18.
Partial top panel 412 includes front and rear end flaps 334, 336, connected by transverse perforated score lines 448, 450, respectively. In contrast, partial top panel 414 is flapless and includes front and rear transverse edges 452, 454, respectively.
The intermediate folded blank is shown in FIG. 20. Side panel 408 is folded at score line 416 to overlie bottom panel 406 and side panel 410. Outer partial top panel 414 is folded at score line 422 to partially overlap inner partial top panel 412. In the resulting intermediate blank 306, gaps 330, 332 are formed between top panel ends flaps 334, 336, and ends flaps 338, 340 of side panel 310.
As shown in FIG. 16, the set-up carton 302 is rectangular in transverse cross-section and is positioned on the carton machine 300 (see FIG. 1) such that the gaps 330, 332, face in a downstream direction and extend substantially vertically.
As shown in FIGS. 16, 17, 18, and 19, the end flaps of the carton 302 are folded in the following order. For purposes of expediency, FIGS. 17-19 illustrate only the front portion of the carton 302, it being understood that the appearance and order of flap closing for the rear portion is identical. As shown in FIG. 1, the bottom panel end flaps 428, 430 are first closed by the front and rear tucker bars 318, 320 of the carton machine 300. The fingers 328 of the tucker bar extend to a point adjacent to the folding rails 314 of the carton machine, so that as the carton 302 is urged into that portion of the machine, the bottom panel end flaps 428, 430 remain closed. The folding rails 314 of the sealing component 316 next fold the top panel end flaps 334, 336. The sealing component 316 then proceeds to fold side panel end flaps 338, 340, then end flaps 436, 438. The sealing machine seals the flaps with an appropriate adhesive. As the sealed cartons 302' are indexed upwardly within the sealing machine 316 the glue sealing the flaps has an opportunity to cool and harden.
The advantage of the specific design of the box blank 404, intermediate folded blank 306, and set-up carton 302 is that the top panel end flaps 334, 336 form gaps 330, 332 with the side panel end flaps 340 which allow the fingers 328 of the tucker bars 318, 320 to extend through and beyond the set-up carton 302 to a point immediately adjacent to the downstream folding rails 314 of the sealing component 316. It is preferable that only the downstream end flaps 334, 336 form a gap with the side panel end flaps 338, 340 since the end flaps 428, 430 must be contacted by the tucker bars and form an appropriate closure for the carton 302.
A user of the carton 302 may gain recess to the envelopes through the partial top panels. First, outer partial top panels 414 is separated from inner partial top panels 412 and pivoted about score line 422. Next, inner partial top panel 412 is separated from flaps 334, 336 at perforated score lines 448, 450 and pivoted about score line 420 away from the carton 302 to expose the contents of the carton. The carton may be resealed by folding partial top flap 414 over partial top flap 312 and tucking tab 426 into slit 424.
While the form of apparatus herein described constitutes a preferred embodiment of this invention, it is to be understood that the invention is not limited to this precise form of apparatus, and that changes may be made therein without departing from the scope of the invention. | An envelope handling system for removing envelopes from an upper level conveyor, placing them in stacks on a lower level bucket conveyor, removing the stacks from the bucket conveyor and side-loading them into cartons, and sealing the cartons, conveying the cartons to a packing area, and forming the cartons into a horizontal column for placement into shipping containers. The system includes a spider feeder for removing the envelopes from an upper level conveyor and discharing them downwardly in a vertical direction, pivoting bottom fingers for receiving envelopes from the feeder and collecting them into a stack, hold back fingers for intercepting envelopes in a second stack above the bottom fingers, and transfer fingers for compressing a stack collected on the bottom fingers and urging the bottom fingers downwardly to place the stack onto the conveyor. The carton A reciprocating ram urges a stack sidewardly from a bucket, a chute and pivoting gate members direct a stack into a set-up carton and compress the stack as it passes therethrough. Reciprocating tucker bars close upstream end flaps of the carton. A helical conveyor channel receives cartons from a sealing machine, orients the cartons to an upright position and deposits the cartons onto a horizontal surface. A reciprocating plate urges the cartons along a channel and a reciprocating plate urges the cartons sidewardly to form the horizontal column. | 8 |
PRIORITY CLAIM
[0001] This application claims priority to U.S. Provisional Patent Application No. 60/726,520, filed Oct. 13, 2005, which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to solar photovoltaic devices and methods for producing those devices.
[0003] A photovoltaic device is a semiconductor device useful for converting solar radiation into electrical energy. Solar photovoltaic systems to this point have not been used extensively in power supplying applications due primarily to the high cost of these systems. The high cost is due in part to the pure single crystal silicon that typically is used in these devices. Further, photovoltaic processing itself is not particularly cost effective for many applications. Solar radiation concentration systems also can be very large, which is undesirable for applications such as home installation.
[0004] Yet another problem with existing solar devices is the need for these devices to actively “track” the sun, or mechanically rotate or pivot about an axis in order to point the device substantially in the direction of the sun. This tracking is needed to obtain sufficient radiation levels throughout the course of the day. A lens or other light-concentrating element 102 can be used to focus light from the sun onto a solar cell 104 , as shown in the configuration 100 of FIG. 1 . This works well while the incoming light is substantially orthogonal to the plane of the concentrating element 102 , but once the light is substantially off-axis the light is no longer concentrated onto the solar cell 104 . As such, it is necessary to rotate the solar device so that the plane of the concentrating element is substantially orthogonal to the incoming solar radiation. The mechanical components necessary to drive the tracking of the device increase the cost and complexity of manufacturing, include moving parts that have long term maintenance issues and increase the probability of device failure, and require excessive space in depth. Without a mechanical tracking system, however, the range of solar angles that can be accepted without a mechanical tracking system is limited.
BRIEF SUMMARY OF THE INVENTION
[0005] Systems and methods in accordance with various embodiments of the present invention provide for the concentration of radiation of various wavelengths and over large regions of incident angle for photovoltaic devices. Such concentration can provide passive tracking of the sun for solar devices, and can allow for the concentration of light without substantial gaps in wavelength or incident angle.
[0006] In one embodiment, a concentrator for a solar device includes a primary hologram formed into a refractive element. The primary hologram is able to focus light onto at least one photovoltaic cell of the solar device. In some embodiments, at least one complimentary hologram is formed into the refractive element, such as into a common region of the refractive element. In other embodiments, a primary hologram is formed into a first layer of the refractive element, with any complimentary holograms being formed into at least a second layer of the refractive element. Each complimentary hologram can be used to focus at least some wavelengths of light not focused by the primary hologram, and/or can focus light for at least some incident angles not focused by the primary hologram.
[0007] Each hologram can be a volume hologram or a phase hologram, for example. The holograms also can each include a series of grooves formed in the refractive element. The primary hologram and complimentary hologram(s) together can provide passive tracking of the sun throughout at least a period of daylight, and/or over a range of incident angles of about +/−45 degrees. The primary hologram and complimentary hologram(s) also can be selected to not cause destructive interference of light redirected thereby.
[0008] The primary hologram and any complimentary holograms can focus incoming light along columns of photovoltaic cells. A reflective backing also can be used to reflect light back through a photovoltaic cell.
[0009] In one embodiment, a concentrator includes a first hologram layer including a first plurality of holograms operable to focus a first set of bands of incident light onto at least one photovoltaic cell. The concentrator also includes a second hologram layer including a second plurality of holograms operable to focus a second set of bands of incident light onto the at least one photovoltaic cell. The first and second bands may or may not overlap.
[0010] In another embodiment, a photovoltaic includes at least one photovoltaic cell and a refractive element including a primary hologram formed therein. The primary hologram is operable to focus solar radiation onto the at least one photovoltaic cell. The refractive element also can include includes at least one complimentary hologram.
[0011] Other embodiments will be obvious to one of ordinary skill in the art in light of the description and figures contained herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Various embodiments in accordance with the present invention will be described with reference to the drawings, in which:
[0013] FIG. 1 shows a concentrating element focusing sunlight onto a solar cell of the prior art;
[0014] FIG. 2 shows a holographic concentrator, with light entering at 0° relative to the normal of the surface, concentrating the light towards the surface of an energy conversion element in accordance with one embodiment of the present invention;
[0015] FIG. 3 shows a holographic concentrator, with light entering at an offset angle relative to the normal of the surface, concentrating the light towards the surface of an energy conversion element in accordance with one embodiment of the present invention;
[0016] FIG. 4 shows a cross-section of an exemplary holographic grating that can be used with the holographic concentrator of FIGS. 2-3 ;
[0017] FIG. 5 shows rays passing through “holes” in a holographic grating in accordance with one embodiment of the present invention;
[0018] FIG. 6 shows multiple layers of holographic gratings in accordance with one embodiment of the present invention;
[0019] FIG. 7 shows a holographic grating focusing light at different angles into columns in accordance with one embodiment of the present invention;
[0020] FIG. 8 shows an example array of 4×4 of photovoltaic cells with interconnection in accordance with one embodiment of the present invention;
[0021] FIG. 9 shows a set of four columns of cells with interconnect wiring in between columns in accordance with one embodiment of the present invention; and
[0022] FIG. 10 shows a holographic grating focusing light at different wavelengths into columns in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Systems and methods in accordance with various embodiments of the present invention can overcome the aforementioned and other deficiencies in existing photovoltaic systems and devices by changing the way in which light is collected and directed toward the photovoltaic elements. In one embodiment, a hologram-based concentrator 202 is used to focus incoming solar radiation onto a photovoltaic element 204 as shown in the configuration 200 of FIG. 2 . In order to also provide for passive tracking, multiple holographic functions can be encoded into a single hologram, multiple holograms, or a set of stacked hologram layers, in a low cost refractive media. Multiple holograms can be selected to concentrate solar radiation onto an array of solar cells over a range of travel of the sun. As shown in the arrangement 300 of FIG. 3 , a hologram-based concentrator 302 can focus incoming radiation onto a photovoltaic device 304 even when the incoming radiation is at an angle θ relative to a normal of the surface of the concentrator.
[0024] There are several different types of holograms that can be used to focus radiation in accordance with various embodiments. One such type is a volume hologram, which typically is formed of a material such as a dichromated gelatin (DCG). Volume holograms include regions embedded within a material that have differing refractive indices, which can be modified by exposure to fringes of laser light. For example, interference patterns can interact with the dichromate to cause changes in the index of refraction within the volume of the dichromated gelatin. There typically is no change to the surface of the material. The changes in refractive index can produce fringes that are angled within the structure. Through proper encoding of the hologram, a lens function can be generated that focuses the light passing through the hologram and exiting the concentrator structure. There can be disadvantages to using dichromated gelatin holograms, however, as these holograms can be more difficult to copy than other holograms. Further, these holograms tend to be expensive and the material itself can be subject to degradation with exposure to ultraviolet (UV) radiation. A UV filter can be placed in front of the hologram to reduce the exposure to UV, allowing a DCG-style hologram to be used as a concentrator. This solution still might not be optimal, however, due to factors such as the replication difficulty and cost.
[0025] A system in accordance with various embodiments provides a solution that can be preferred for many applications utilizing a phase hologram in a concentrator structure. A phase hologram typically takes the form of a series of grooves formed in a refractive medium. An example of a series of grooves 402 , or grating structure, acting as a phase hologram is shown in the cross-section of the arrangement 400 of FIG. 4 . The grooves here are shown for illustrative purposes as a simple sine wave, exaggerated in dimension, but it should be understood that any of a number of groove configurations can be used as would be understood to one of ordinary skill in the art. The grating can be stamped or otherwise formed into a refractive material using various techniques known in the art. The period of each grating can be on the order of the wavelength of the incoming light. Where the incoming light contains a wide range of wavelengths, a number of gratings can be used to capture a desired range of wavelengths. The hologram also can have beveled edges, similar to a Fresnel lens as known in the art.
[0026] Light passing through the grooves 402 can undergo a change in velocity, which effectively changes the phase relationship of wavefronts entering the medium. Altering the phase relation of the wavefronts causes refraction at an angle determined by factors such as wavelength, angle of incidence, groove spacing and amplitude, and the refractive index of the medium. The grooves, or other changes in surface topology, can be generated to correspond to a desired fringe structure. In one example, a resist can be deposited on a glass plate then exposed to a holographic pattern using object and reference beams as known in the art for producing holograms. Once the resist is developed there is a corresponding topological change in the resist, comprising the holographic function. As light passes through the undulating surface comprising the hologram, the changes in speed and phase of the light can change the direction of the light passing through the concentrator structure, effectively producing a lens function that is very similar to that of the DCG-style hologram described above. The phase hologram, however, can be much easier and cheaper to produce, and can offer less degradation over time upon exposure to radiation.
[0027] In one embodiment, a holographic concentrator consists of a refractive material such as plastic or glass. A holographic pattern is stamped, embossed, or otherwise formed into one or more layers of the refractive material. The holographic function itself can consist of one or more multiple holographic patterns. The patterns can be encoded into one or more layers, regions, and/or surfaces of the refractive material, as described below. In one embodiment, each pattern encodes the function of a convex lens, such that incoming light is focused down to a point, line, rectangle, or other similar shape or spot, with at least one dimension being smaller than the holographic element. By focusing the light to such shapes, an array of individual concentrator elements can be used wherein each element directs light to an array of energy conversion elements, such as silicon photovoltaic cells. Alternatively, multiple holographic patterns can be used to focus incoming light on a subset of possible solar cell locations, such that fewer solar cells can be used and the cost of the photovoltaic device can be decreased.
[0028] For each holographic pattern, there can be a corresponding output function that causes light entering at a particular angle, or within a particular angular range, to focus onto an energy conversion element. Over some range of input angles, such as angled over a 10° spread (+/−5°), the hologram can efficiently focus the incoming light onto the energy conversion element. Outside that range, that particular pattern can have little or no effect on the incoming light. For instance, the arrangement 500 of FIG. 5 shows a first pair of rays 504 that are at an angle α with respect to a normal 508 to the surface of the hologram concentrator 502 . Since α is outside the angular range of the hologram, the rays simply pass through without being redirected by the concentrator. In contrast, a second pair of rays 506 is at an angle θ with respect to a normal 508 to the surface of the hologram concentrator. Since θ is within the angular range of the hologram, the rays are redirected and focused by the concentrator.
[0029] In order to focus light over a wider range of incoming light angles, additional holograms can be encoded into the surface of the refractive medium. Holograms can be combined as known in the art, similar to adding together waves of differing frequencies to form a complex wave function. For example, the grating in FIG. 4 is shown as a single phase hologram, but there can be multiple grating shapes summed into a grating profile. For example, a layer might have a shape that would result from adding together six sine waves of different frequency. It has been found that for certain embodiments the efficiency of a multiple hologram concentrator is actually greater than that of single holograms for a number of angular positions.
[0030] While it would seem that an entire angular range could be captured simply by using a sufficient number of hologram patterns, it was found that simply increasing the number of hologram patterns in a layer, and thereby decreasing the angular spacing, can cause destructive interference of the light from different angles. This interference can render the device inoperable. In order to encode multiple holograms such that the holograms each provide the described focusing function, care should be taken to ensure that the diffraction angles of each of the patterns do not destructively interfere with each other. For practical applications which require high efficiency, the input angles of each holographic pattern encoded into a material can require a certain minimum spacing. The minimum spacing can vary with angle. In one embodiment, it was found that a maximum of five or six holograms could be successfully encoded into a layer without (or with minimum) interference between the holograms. The number of holograms for different embodiments can vary, due to factors such as the wavelength of light used and the periods of the holograms. By encoding at most this number of holograms, a concentrator can effectively focus light over the ranges for each individual hologram.
[0031] The angular range is important for many applications because, over the course of the day as the sun moves across the sky, there is a limited angular motion over which any one particular hologram will be functional. Experimentally, it has been seen that at least some holograms are only functional between about +/−5° to +/−10° of variation. Outside of this functional range, light simply passes through the hologram without being redirected. As light begins to enter this range, some of the light will begin to be diffracted by the hologram. There will be some angular range within the functional range where a maximum efficiency is obtained. As the light nears the other end of the range, the efficiency can again taper off. By encoding multiple holograms, such as by using multiple exposures, then encoding these multiple holograms into the material, a number of bands can be obtained comprising encoded positions, or ranges of angles where at least one of the multiple holograms is functional. Light outside of these encoded ranges will essentially pass through the patterns. Within these ranges light will be refracted and focused down onto the solar cells.
[0032] A potential problem with combining multiple holograms into a single surface layer in this way comes in the fact that the combined holograms can result in “holes” or “gaps” in the range of operable angles of sunlight relative to the concentrator. Holes, as they are called herein, refer to regions bounded by certain ranges of input angles in which that particular layer essentially has little or no effect. Light entering in one of these input angle ranges will pass directly through the hologram, without being focused or concentrated onto the underlying solar cells. These holes can lead to variations in the amount of light focused throughout the course of a day
[0033] One way to address this problem is to utilize at least one additional layer of multiple holographic functions. To compensate for holes, as well as to cover a large angular range, multiple layers of holograms can be used. In some embodiments two layers may be sufficient, while other embodiments may require three or more. A second hologram layer, which can be positioned under the first or “top” hologram layer, can encode angles that are not encoded by the first hologram layer. Light that passes through the holes in the top hologram layer can be focused by a second (or subsequent) layer down onto the solar cells. If additional layers are used, light passing through holes in the first two layers can be encoded by one of these additional layers.
[0034] Use of multiple layers is shown, for example, in the arrangement 600 of FIG. 6 . As can be seen in the Figure, a pair of rays 606 coming in at a first angle is passed directly through the first hologram layer 602 , through a “hole” in the upper layer. These rays are incident upon a second hologram layer 604 at the same angle, but are redirected by the second layer. A second pair of rays 608 is incident upon the first hologram layer 602 at a second angle, and is redirected by the first hologram layer. These redirected rays then pass directly through the second hologram layer 604 . The holograms in the first and second layers can be selected such that the holograms in the second layer redirect rays for the holes in the first layer, and vice versa, such that substantially all angles over a given overall angular range are directed by (at least) one of the hologram layers. It can be undesirable to have the ranges of the hologram layers overlap in some embodiments, while other embodiments might utilize the additional focusing ability. In one such device, multiple holographic functions are separately encoded in the top and bottom surfaces of a refractive medium.
[0035] There can be an issue with interaction from the “top” hologram and a second hologram layer “underneath.” Normally, light is always focused in the same way, in that light of the appropriate angular range, being focused by the top or a subsequent hologram layer, almost always follows the same path exiting that hologram layer, except for very small angular changes through a second or subsequent hologram layer. It then is normally necessary in this embodiment for the second or subsequent holograms to simply pass through the focused rays that have passed through from the top or previous hologram layers. Multiple layers can be used to cover the range of tracking angles chosen to be encoded into the holograms. For practical purposes, there may be no point to encoding angles greater than +/−45°. At larger angles the sun may be so far off-axis that the amount of capturable light that would produce useful power might be so low as to not be useful. As such, a range can be defined over which one may choose to define the optimal set of holograms to encode light. This range can balance the capturable light at farther off-axis angles with the cost for configuring hologram layers to capture those angles.
[0036] In one example, a concentrator can utilize three stacked gratings, a top grating, a middle grating, and a bottom grating, although it should be understood that designations such as top and bottom are used for simplicity of understanding and explanation and should not be read as required orientations or limitations on the embodiments described herein. In this example the top grating, or the grating upon which incident radiation first impinges, is selected to redirect light incident at an angle of −50°±10° and +10°±10°, in order to cover a range of −60° to −40° and 0° to +20° relative to normal. The middle grating is selected to redirect light incident at an angle of −30°±10° and +30°±10°, in order to cover a range of −40° to −20° and +20° to +40° relative to normal. The bottom grating is selected to redirect light incident at an angle of −10°±10° and +50°±10°, in order to cover a range of −20° to 0° and +40° to +60° relative to normal. The total effective range of the concentrator is then approximately −60° to +60° relative to normal.
[0037] Multiple sets of patterns can be designed to complement each other to effectively eliminate holes as discussed above. Another advantage to using multiple sets of patterns is the ability for each hologram to focus light over the effective range to a specific location. For example, as shown in the arrangement 700 of FIG. 7 (and greatly exaggerated for illustrative purposes), the concentrator 702 , which can include multiple layers and/or multiple holograms, can be designed such that light incident at different angles is focused (via different holograms) to different locations 704 , 706 . The ability to selectively focus light allows solar devices to be used without a continuous region of solar conversion elements. For example, a solar device might include a tightly-packed array of solar cells 800 , such as is shown in the arrangement of FIG. 8 and described in U.S. patent application Ser. No. 11/525,562, filed Sep. 21, 2006, [ATTY DOCKET NO. 026238-000110US], which is hereby incorporated herein by reference. The ability to selectively focus light allows the solar cells to be formed into columns 902 , such as is shown in the arrangement 900 of FIG. 9 and also described in the cited application, whereby all incoming light can be focused onto one of these columns depending upon the incident angle and hologram redirecting the light. Using columns of cells, instead of tightly-packed arrays, can greatly decrease the cost of the device.
[0038] The holographic patterns also can be formed in a refractive medium using grooves that are wavelength-specific. An advantage to wavelength-specific holograms is that light of different wavelengths can be selectively directed via the different holograms. For example, with an angle of incidence θ for incoming light (relative to normal), light of different wavelengths 1002 , 1004 can focus to different positions along the axis between the hologram and focus point. Again, the figure is exaggerated for illustration. With light entering at input angles other than 0°, the focus point of different wavelengths can be spread laterally across the energy conversion element. Care can be taken in the design of the hologram patterns, and the spacing of the conversion elements, such that the bulk of the desired wavelengths of light converge on the energy conversion elements over the desired range of input angles.
[0039] Different wavelengths of light can spread laterally over the solar cells underneath. The spectral spreading can have practical aspects in terms of how high a concentration factor can be implemented. There also can be ramifications in terms of the spacing between the hologram(s) and the solar cell. In general, increasing the spacing can help spectral spreading, but can be a disadvantage as keeping the hologram as close as possible to the solar cells requires less filler material. An advantage of a “squiver” device such as that shown in FIGS. 8 and 9 and described in U.S. patent application Ser. No. 11/525,562, filed Sep. 21, 2006, [ATTY DOCKET NO. 026238-000110US], is that the squivers can be relatively small, and can be aligned in columns that are relatively small, such that there can be relatively small spacings between the holograms and the squivers. This spectral splitting also can be used to an advantage, as solar cells can be used that have increased efficiency for certain wavelengths. For example, some cells might be more infrared (IR) sensitive, and produce higher output at IR wavelengths, while some might be more efficient for visible wavelengths. The holograms can be encoded with the ability to preferentially focus light for one strip of solar cells that use one band (visible) of light, and for an adjacent strip of cells that is more efficient for converting another spectral band (IR). This can be done through encoding the holograms to diffract the light preferentially into the desired bands.
[0040] In an alternate embodiment, a holographic pattern can be encoded with multiple patterns that separate bands of wavelengths. For example, each of a number of different bands of wavelength can converge on a separate energy conversion element. These separate conversion elements each can be tuned to provide maximum conversion efficiency for a particular band of wavelengths. Since most energy conversion materials exhibit maximum conversion efficiency over only a certain range of wavelengths, this technique can be used to maximize the conversion of all available wavelengths of incoming illumination. Each of the multiple conversion elements can be tuned to maximize specific bands of light. The holographic patterns can be designed to direct these separate bands to the separate elements.
[0041] Using multiple holograms with columns of cells allows the sunlight to be pointed onto the columns as the earth rotates, providing one-dimensional passive tracking as described above. This one-dimensional tracking can be sufficient, as the seasonal variations in sun position relative to the columns results in an “up and down” movement of the light focused by the lens structures. If the solar cells are arranged in columns having a longitudinal axis that is substantially aligned with this “up and down” direction, the elongated spot of light focused onto each column will simply move along that longitudinal axis, such that substantially the same amount of light is focused over the majority of the columns. There can be slight variations in the amount of light focused at the ends of the columns, but the amount of overall variation in light intensity focused on the cells can be minimal. A simple way to take advantage of all the light is to have the light spot generated by each cylindrical lens be of a length less than the length of the respective column, such that as the spot moves up and down along the column, the ends of the spot never goes outside the column of cells. A determination can be made as to whether the additional size and cost of the longer columns of cells is offset by the benefit of the additional light energy captured by these longer columns.
[0042] There can always be some inefficiency in such a device. There can be losses from front and back surfaces of each hologram, as well as transmission efficiencies for light passing through the holograms. Typical holograms are capable of 70-80% transmission efficiencies, with 70-80% of the incoming light being diffracted down to the solar cells or target surface. While some losses are inherent in a structure such as this, an advantage is that the assembly process is very inexpensive. In one exemplary process, where the acrylic/plastic has to be stamped anyway, the top hologram layer can be obtained without additional process steps simply by placing the stamp for the hologram on one side of the stamper used for the acrylic/plastic. In the case of plastic, where there can be a cover surface anyway, the other hologram can be stamped into that glass, or another thin piece of plastic applied over that glass. The ultimate advantage is that the major cost in the modules is the processing and the silicon in the solar cells themselves. The cost of the plastic or the cover glass is much lower than this cost, although at some point it can become comparable. Somewhere in the range of 2X-4X, there can be an advantage to using a concentrator and a smaller number of cells, and getting the cost of the overall module significantly lower. For the same area, the power output may not be as great due to the efficiency losses, but it might be 70-80% as efficient. This still is a reasonably good efficiency for a system, and if the cost is reduced by 2X-4X, it is obviously a significant improvement in cost. The cost per Watt is probably the dominating factor for many of these devices, and one of the desires for solar energy, so this provides a major advantage.
[0043] In a production environment, it can be too expensive and inefficient to form each hologram individually. Once a desired topology is determined and created for a first device, a mold can be made of that topology, such as may be encoded into a resist layer as described elsewhere herein. Material can be deposited onto the resist that will build up a metal layer, such as a layer of nickel, which will form a “daughter” stamper as known in the art. From the daughter stamper, a “master” stamper can be created that will be used to actually stamp the hologram pattern into the plastic, glass, or other refractive material being used. Such a process can be tricky for reasons such as thermal expansion. The stamper can expand if formed from plastic or acrylic, but at different rates, and will not expand as much if formed from a material such as glass as if formed from nickel or plastic. There then can be compensation made for thermal expansion effects in the selected material.
[0044] In many embodiments, each hologram is substantially parallel to the solar cell(s). In other embodiments, the cells can be at a right angle to the hologram, such that the light would be focused onto the cells at right angles. Such cells could fall or flow into slots, such as vertically oriented slots in a piece of glass or plastic. The light then can be focused onto those slots. Other embodiments, structures, and arrangements can be used without departing from the teachings herein.
[0045] In almost every embodiment there will be a situation, particularly for IR wavelengths, where light will pass all the way through the cells. As a consequence the back of the cell (and anything beyond the cell) can have important properties. There can be an advantage to directly placing a metal, such as a metal interconnect, or other reflective material on the backside of the cell, as that material/metal can substantially reflect all light impinging thereon. The reflected light can travel back through the cell, giving the photons a second opportunity to interact with the solar cells and be converted to energy.
[0046] If there is a Mylar® or similar backing (Mylar® is a registered trademark of DuPont of Des Moines, Iowa), an insulating backing behind the cell, or a gap and then a backing material, which can have a metal interconnect or contact layer behind that, there is an additional opportunity for interaction, which can cause reflection losses and interactions with both the surface of the material and the inner material. Such a material can degrade due to UV exposure, although the material may not be subjected to much UV as much of the radiation will be blocked by the cell. Because of issues such as these, many embodiments do not use such backings. If a backing is used, other than a material contact or interconnect, it can be desired to utilize a sufficiently reflective backing. There may, however, be some advantage to a backing being diffuse, instead of simply reflecting light back directly through the cell. There can be an advantage to reflecting light at oblique angles, as that would give more opportunity for the photons to interact with the cell and convert more light energy. In order to get the reflective and diffuse characteristics, an interconnect can be used that is reflective and tends to have a matte finish, rather than a smooth surface.
[0047] The holograms can be selected and combined using any combination of experimentation, mathematics, and modeling as known in the art. The holograms can be selected based on any of a number of factors, such as desired wavelength ranges, bands, and efficiencies.
[0048] It should be recognized that a number of variations of the above-identified embodiments will be obvious to one of ordinary skill in the art in view of the foregoing description. Accordingly, the invention is not to be limited by those specific embodiments and methods of the present invention shown and described herein. Rather, the scope of the invention is to be defined by the following claims and their equivalents. | A solar energy system can include at least one holographic optical element to encode the focusing of solar radiation. Multiple holograms and/or multiple layers can be used to focus light over a band(s) of angles and/or wavelengths onto an array of solar cell elements. The selection of holograms in a concentrator can allow a photovoltaic device to receive light over a wide range of incident angles, and can allow for the receiving of a wide band of wavelengths without inoperable gaps in angle of incidence or wavelength. This range of incident angles for solar cells allows the solar cells to receive light over a large period of daylight without the need to mechanically rotate or pivot the device in order to track the movement of the sun throughout the daylight period. | 7 |
This application claims the benefit of prior U.S. provisional application Ser. No. 60/028,504 flied Oct. 16, 1996.
BACKGROUND OF THE INVENTION
The present invention relates to the discovery of novel, low molecular weight, non-peptide inhibitors of matrix metalloproteinases (e.g. gelatinases, stromelysins and collagenases) and TNF-α converting enzyme (TACE, tumor necrosis factor-α converting enzyme) which are useful for the treatment of diseases in which these enzymes are implicated such as arthritis, tumor metastasis, tissue ulceration, abnormoal wound healing, periodontal disease, bone disease, proteinuria, aneurysmal aortic disease, degenerative cartilage loss following traumatic joint injury, demyelinating diseases of the nervous system and HIV infection.
Matrix metalloproteinases (MMPs) are a group of enzymes that have been implicated in the pathological destruction of connective tissue and basement membranes Woessner, J. F., Jr. FASEB J. 1991, 5, 2145; Birkedal-Hansen, H.; Moore, W. G. I.; Bodden, M. K.; Windsor, L. J.; Birkedal-Hansen, B.; DeCarlo, A.; Engler, J. A. Crit. Rev. Oral Biol. Med. 1993, 4, 197; Cawston, T. E. Pharmacol. Ther. 1996, 70, 163; Powell, W. C.; Matrsian, L. M. Cur. Top. Microbiol. and Immunol. 1996, 213, 1!. These zinc containing endopeptidases consist of several subsets of enzymes including collagenases, stromelysins and gelatinases. Of these classes, the gelatinases have been shown to be the MMPs most intimtly involved with the growth and speead of tumors, while the collagenases have been associated with the pathogenesis of osteoarthritis Howell, D. S.; Pelletier, J.-P. In Arthritis and Allied Conditions; McCarthy, D. J.; Koopman, W. J., Eds.; Lea and Febiger: Philadelphia, 1993; 12th Edition Vol. 2, pp. 1723; Dean, D. D. Sem. Arthritis Rheum. 1991, 20, 2; Crawford, H. C.; Matrisian, L. M. Invasion Metast. 1994-95, 14, 234; Ray, J. M.; Stetler-Stevenson, W. G. Exp. Opin. Invest. Drugs, 1996, 5, 323!.
It is known that the level of expression of gelatinase is elevated in malignancies, and that gelatnase can degrade the basement membrane which may lead to tumor metastasis Powell, W. C.; Matrisian, L. M. Cur. Top. Microbiol. and Immunol. 1996, 213, 1; Crawford, H. C.; Matrisian, L. M. Invasion Metast. 1994-95, 14, 234; Ray, J. M.; Stetler-Stevenson, W. G. Exp. Opin. Invest. Drugs, 1996, 5, 323; Himelstein, B. P.; Canete-Soler, R.; Bernhard, E. J.; Dilks, D. W.; Muschel, R. J. Invasion Metast. 1994-95, 14, 246; Nuovo, G. J.; MacConnell, P. B.; Simsir, A.; Valea, F.; French, D. L. Cancer Res. 1995, 55, 267-275; Walther, M. M.; Levy, A.; Hurley, K.; Venzon, D.; Linehen, W. M.; Stetler-Stevenson, W. J. Urol. 1995, 153 (Suppl. 4), 403A; Tokuraku, M; Sato, H.; Murakami, S.; Okada, Y.; Watanabe, Y.; Seiki, M. Int. J. Cancer, 1995, 64, 355; Himelstein, B.; Hua, J.; Bemhard, E.; Muschel, R. J. Proc. Am. Assoc. Cancer Res. Ann. Meet. 1996, 37, 632; Ueda, Y.; Imai, K.; Tsuchiya, H.; Fujimoto, N.; Nakanishi, I.; Katsuda, S.; Seiki, M.; Okada, Y. Am. J. Pathol. 1996, 148, 611; Gress, T. M.; Mueller-Pillasch, F.; Lerch, M. M.; Friess, H.; Buechler, M.; Adler, G. Int. J. Cancer, 1995, 62, 407; Kawashima, A.; Nakanishi, I.; Tsuchiya, H.; Roessner, A.; Obata, K.; Okada, Y. Virchows Arch., 1994, 424, 547-552.!. Angiogenesis, required for the growth of solid tumors, has also recently been shown to have a gelatinase component to its pathology Crawford, H. C; Matrisian, L. M. Invasion Metast. 1994-95, 14, 234; Ray, J. M.; Stetler-Stevenson, W. G. Exp. Opin. Invest. Drugs, 1996, 5, 323.!. Furthermore, there is evidence to suggest that gelatinase is involved in plaque rupture associated with atherosclerosis Dollery, C. M.; McEwan, J. R.; Henney, A. M. Circ. Res. 1995, 77, 863; Zempo, N.; Koyama, N.; Kenagy, R. D.; Lea, H. J.; Clowes, A. W. Arterioscler. Thromb. Vasc. Biol. 1996, 16, 28; Lee, R. T.; Schoen, F. J.; Loree, H. M.; Lark, M. W., Libby, P. Arterioscler. Thromb. Vasc. Biol. 1996, 16, 1070.!. Other conditions mediated by MMPs are restenosis, MMP-mediated osteopenias, inflammatory diseases of the central nervous system, skin aging, tumor growth, osteoarthritis, rheumatoid arthritis, septic arthritis, corneal ulceration, abnormal wound healing, bone disease, proteinuria, aneurysmal aortic disease, degenerative cartilage loss following traumatic joint injury, demyelinating diseases of the nervous system, cirrhosis of the liver, glomerular disease of the kidney, premaure rupture of fetal membranes, inflanmatory bowel disease, periodontal disease, age related maclar degeneration, diabetic retinopathy, proliferative vitoretinopathy, retinopathy of prematurity, ocular inflam on, keratoconus, Sjogren's syndrome, myopia, ocular tumors, ocular angiogenesis/neovascularization and corneal graft rejection.
The hypothesis that MMPs are important mediators of the tissue destruction that occurs in arthritis has long been considered, since it was first recognized that these enzymes are capable of degrading collagens and proteoglycans which are the major structural components of cartilage Sapolsky, A. I.; Keiser, H.; Howell, D. S.; Woessner, J. F., Jr.; J. Clin. Invest. 1976, 58, 1030; Pelletier, J.-P.; Martel-Pelletier, J.; Howell, D. S.; Ghandur-Mnaymneh, L.; Enis, J. E.; Woessner, J. F., Jr., Arthritis Rheum. 1983, 26, 63.!, and continues to develop as new MMPs are identified. For example, collagenase-3 (MMP-13) was cloned from breast cancer cells in 1994, and the first report that it could be involved in arthritis appeared in 1995 Freiji, J. M.; Diez-Itza, L; Balbin, M.; Sanchez, L. M.; Blasco, R.; Tolivia, J.; Lopez-Otin, C. J. Biol. Chem. 1994, 269, 16766; Flannery, C. R.; Sandy, J. D. 102-17, 41st Ann. Meet. Orth. Res. Soc. Orlando, Fla. Feb. 13-16, 1995.!. Evidence is accumulating that implicates MMP-13 in the pathogenesis of arthritis. A major structural component of articulr cartilage, type II collagen, is the preferred substrate for MMP-13 and this enzyme is significantly more efficient at cleaving type II collagen than the other collagenases Knauper, V.; Lopez-Otin, C.; Smith, B.; Knight, G.; Murphy, G. J. Biol. Chem., 1996, 271, 1544-1550; Mitchell, P. G.; Magna, H. A.; Reeves, L. M.; Lopresti-Morrow, L. L.; Yocum, S. A.; Rosner, P. J.; Geoghegan, K. F.; Hambor, J. E. J. Clin. Invest. 1996, 97, 761.!. MMP-13 is produced by chondrocytes, and elevated levels of MMP-13 has been found in human osteoarthitic tissues Reboul, P.; Pelletier, J-P.; Hambor, J.; Magna, H.; Tardif, G.; Cloutier, J-M.; Martel-Pelletier, J. Arthritis Rheum. 1995, 38 (Suppl. 9), S268; Shlopov, B. V.; Mainardi, C. L.; Hasty, K. A. Arthritis Rheum. 1995, 38 (Suppl. 9), S313; Reboul, P.; Pelletier, J-P.; Tardif, G.; Cloutier, J-M.; Martel-Pelletier, J. J. Clin. Invest. 1996, 97, 2011!. Potent inhibitors of MMPs were described over 10 years ago, but the poor bioavailability of these arliy peptidic, substrate mimeti MMP inhibitors precluded their evaluation in animal models of arthritis. More bioavailable, non-peptidic MMP inhibitors may be preferred for the treatment of diseases mediated by MMPs.
TNF-α converting enzyme catalyzes the formation of TNF-α from membrane bound TNF-α precursor protein. TNF-α is a pro inflao iatory cytokine that is now thought to have a role in rheumatoid arthritis, septic shock, graft rejection, insulin resistance and HIV infection in addition to its well documented antitumor properties. For example, research with anti-TNF-α antibodies and transgenic animas has demonstrated that blocking the formation of TNF-α inhibits the progression of arthritis Rankin, E. C.; Choy, E. H.; Kassimos, D.; Kingsley, G. H.; Sopwith, A. M.; Isenberg, D. A.; Panayi, G. S. Br. J. Rheumatol. 1995, 34, 334; Pharmaprojects, 1996, Therapeutic Updates 17 (Oct.), au197-M2Z.!. This observation has recently been extended to humans as well. Other conditions mediated by TNF-α are congestive heart failure, cachexia, anorexia, inflammation, fever, irmmrtory disease of the central nervous system, and inflammatory bowel disease.
It is expected that small molecule inhibitors of gelatinase and TACE therefore have the potential for treting a variety of disease states. While a variety of MMP and TACE inhibitors have been identified and disclosed in the literature, the vast majority of these molecules are peptidic or peptide-like compounds that may have bioavailability and pharmacokinetic problems that would limit their clinical effectiveness. Low molecular weight, potent, long-acting, orally bioavailable inhibitors of gelatinases, collagenases and/or TACE are therefore highly desirable for the potential chronic treatment of the above mentioned disease states. Several non-peptidc, sulfur-containing hydroxamic acids have recendy been disclosed and are listed below.
U.S. Pat. Nos. 5,455,258, 5,506,242 and 5,552,419, as well as European patent application EP606,046A1 and WIPO international publications WO96/00214 and WO97/22587 disclose non-peptide matrix metalloproteinase inhibitors of which the compound CGS27023A is representative. The discovery of this type of MMP inhibitor is further detiled by MacPherson, et. al. in J. Med. Chem., (1997),40, 2525. Additional publications disclosing sulfonamide based MMP inhibitors which are variants of the sulfonamide-hydroxamate shown below, or the analogous sulfonamide-carboxylates, are European patent application EP-757984-A1 and WIPO international publications WO95/35275, WO95/35276, WO96/27583, WO97/19068 and WO97/27174. ##STR2##
Publications disclosing β-sulfonamide-hydroxamate MMP inhibitor analogs of CGS 27023A in which the carbon alpha to the hydroxamic acid has been joined in a ring to the sulfonamide nitrogen, as shown below, include WIPO international publications WO96/33172 and WO97/20824. ##STR3##
The German patent application DE19,542,189-A1 discloses additional examples of cylic sulfonamides as MMP inhibitors. In this case the sulfonamide-contning ring is fused to a phenyl ring to form an isoquinoline. ##STR4##
Analogs of the sulfonamide-hydroxamate MMP inhibitors in which the sulfonamide nitrogen has been replaced by a carbon atom, as shown in the general stmcture below, are European patent application EP-780386-A1 and WIPO international publication WO97/24117. ##STR5##
SUMMARY OF THE INVENTION
The TACE and MMP inhibiting orthosulfonamido aryl hydroxamic acids of the present invention are represented by the formula ##STR6## where the hydroxamic acid moiety and the sulfonamido moiety are bonded to adjacent carbons of group A where:
A is phenyl or naphthyl, optionally substituted by R 1 , R 2 , R 3 and R 4 ;
Z is aryl, heteroaryl, or heteroaryl fused to a phenyl,
where aryl is phenyl or naphthyl optionally substituted by R 1 , R 2 , R 3 and R 4 ;
heteroaryl is a 5-6 membered heteroaromatic ring having from 1 to 3 heteroatoms independently selected from N, O, and S, and optionally substituted by R 1 , R 2 , R 3 and R 4 ;
and when heteroaryl is fused to phenyl, either or both of the rings can be optionally substituted by R 1 , R 2 , R 3 and R 4 ;
R 1 , R 2 , R 3 and R 4 are independently --H, --COR 5 , --F,--Br, --Cl, --I, --C(O)NR 5 OR 6 ,--CN, --OR 5 , --C 1 -C 4 -perfluoroalkyl, --S(O) x R 5 where x is 0-2, --OPO(OR 5 )OR 6 , --PO(OR 6 )R 5 , --OC(O)NR 5 R 6 , --COOR 5 , --CONR 5 R 6 , --SO 3 H, --NR 5 R 6 , --NR 5 COR 6 , --NR 5 COOR 6 , --SO 2 NR 5 R 6 , --NO 2 , --N(R 5 )SO 2 R 6 , --NR 5 CONR 5 R 6 , --NR 5 C(═NR 6 )NR 5 R 6 , 3-6 membered cycloheteroalkyl having one to three heteroatoms independently selected from N, O, and S and optionally having 1 or 2 double bonds and optionally substituted by one to three groups each selected independently from R 5 ; -aryl or heteroaryl as defined above, biphenyl optionally substituted by one to four groups each selected independently from R 4 , --SO 2 NHCOR 5 or --CONHSO 2 R 5 where R 5 is not H, -tetrazol-5-yl, --SO 2 NHCN, --SO 2 NHCONR 5 R 6 or straight chain or branched -C 1 -C 6 alkyl, -C 2 -C 6 -alkenyl, or -C 2 -C 6 -alkynyl, or -C 3 -C 6 -cycloalkyl optionally having 1 or 2 double bonds each optionally substituted with --COR 5 , --CN, -C 2 -C 6 alkenyl, -C 2 -C 6 alkynyl, --OR 5 , -C 1 -C 4 -perfluoroalkyl, --S(O) x R 5 where x is 0-2, --OC(O)NR 5 R 6 , --COOR 5 , --CONR 5 R 6 , --SO 3 H, --NR 5 R 6 , --NR 5 COR 6 , --NR 5 COOR 6 , --SO 2 NR 5 R 6 , --NO 2 , --N(R 5 )SO 2 R 6 , --NR 5 CONR 5 R 6 , -C 3 -C 6 cycloalkyl as defined above, 3-6 membered cycloheteroalIyl as defined above, aryl or heteroaryl as defined above, biphenyl, --SO 2 NHCOR 5 or --CONHSO 2 R 5 where R 5 is not hydrogen; --PO(OR 5 )OR 6 , --PO(OR 6 )R 5 , -tetrazol-5-yl, C(O)NR 5 OR 6 , --NR 5 C(═NR 6 )NR 5 R 6 ,--SO 2 NHCONR 5 R 6 or --SO 2 NHCN;
with the proviso that when R 1 and R 2 are on adjacent carbons of A, R 1 and R 2 together with the carbons to which they are attached can form a 5 to 7 membered saturated or unsaturated heterocyclic ring or a 5-6 membered heteroaryl ring, each having 1 to 3 heteroatoms independently selected from O, S, or N, and each optionally substituted by one to four groups each selected independently from R 4 ; or a 5 to 7 membered saturated or unsaturated carbocyclic ring optionally substituted by one to four groups each selected independently from R 4 ;
R 5 and R 6 are independently H, aryl and heteroaryl as defined above, -C 3 -C 6 -cycloalkyl as defined above, -C 3 -C 6 -cycloheteroalkyl as defined above, -C 1 -C 4 -perfluoroalkyl, or straight chain or branched -C 1 -C 6 alkyl, -C 2 -C 6 -alkenyl, or -C 2 -C 6 -alkynyl each optionally substituted with --OH, --COR 8 , --CN, --C(O)NR 8 OR 9 , -C 2 -C 6 -alkenyl, -C 2 -C 6 -alkynyl, --OR 8 , -C 1 -C 4 -perfluoroakyl, --S(O) x R 8 where x is 0-2, --OPO(OR 8 )OR 9 , --PO(OR 8 )R 9 , --OC(O)NR 8 R 9 , --COOR 8 , --CONR 8 R 9 , --SO 3 H, --NR 8 R 9 ,--NCOR 8 R 9 , --NR 8 COOR 9 , --SO 2 NR 8 R 9 , --NO 2 , --N(R 8 )SO 2 R 9 , --NR 8 CONR 8 R 9 , -C 3 -C 6 cycloalkyl as defined above, 3-6 rnembered cycloheteroalkyl as defined above, aryl or heteroaryl as defined above, --SO 2 NHCOR 8 or --CONHSO 2 R 8 where R 8 is not hydrogen, -tetrazol-5-yl, --NR 8 C(═NR 9 )NR 8 R 9 , --SO 2 NHCONR 8 R 9 , or --SO 2 NHCN;
R 7 is hydrogen, straight chain or branched -C 1 -C 6 -alkyl, -C 2 -C 6 -alkenyl, or -C 2 -C 6 -alkynyl each optionally substituted with --OH, --COR 5 , --CN, -C 2 -C 6 alkenyl,-C 2 -C 6 -alkynyl, --OR 5 ,-C 1 -C 4 -perfluoroalkyl, --S(O) x R 5 where x is 0-2, --OPO(OR 5 )OR 6 , --PO(OR 5 )R 6 , --OC(O)NR 5 R 6 , --COOR 5 , --CONR 5 R 6 , --SO 3 H, --NR 5 R 6 ,--NR 5 COR 6 , --NR 5 COOR 6 , --SO 2 NR 5 R 6 , --NO 2 , --N(R 5 )SO 2 R 6 , --NR 5 CONR 5 R 6 ,-C 3 -C 6 cycloalkyl as defined above, -C 3 -C 6 -cycloheteroalkyl as defined above, -aryl or heteroaryl as defined above, --SO 2 NHCOR 5 or --CONHSO 2 R 5 where R 5 is not hydrogen, -tetrazol-5-yl, --NR 5 C(═NR6)NR 5 R 6 , --C(O)N R 5 OR 6 , --SO 2 NHCONR 5 R 6 or --SO 2 NHCN;
or R 7 is phenyl or naphthyl, optionally substituted by R 1 , R 2 , R 3 and R 4 or a 5 to 6 membered heteroaryl group having 1 to 3 heteroatoms selected independendy from N, O, and S and optionally substituted by R 1 , R 2 , R 3 and R 4 ;
or R 7 is C 3 -C 6 cycloalkyl or 3-6 membered cycloheteroalkyl as defined above;
or R 7 CH 2 --N--A--, where A is as defined above, can form a non-aromatic 1,2-benzo-fused 7-10 membered heterocyclic ring optionally containing an additional heteroatom selected from O, S and N wherein said heterocyclic ring may be optionally fused to another benzene ring;
R 8 and R 9 are independently H, aryl or heteroaryl as defined above, -C 3 -C 7 -cycloalkyl or 3 to 6 membered cycloheteroalkyl as defined above, -C 1 -C 4 -perfluoroalkyl, straight chain or branched -C 1 -C 6 -alkyl, -C 2 -C 6 -alkenyl, or -C 2 -C 6 -alkynyl, each optionally substituted with hydroxy, alkoxy, aryloxy, -C 1 -C 4 -perfluoroalkyl, amino, mono- and di-C 1 -C 6 -alkylamino, carboxylic acid, carboalkoxy and carboaryloxy, nitro, cyano, carboxamido primay, mono- and di-C 1 -C 6 -alkylcarbamoyl;
and the pharmaceutically acceptable salts thereof and the optical isomers and diastremrs thereof.
Preftrred compounds are those wherein both of the carbons of A adjacent to the carbon bearing the sulfonamido group have a substituent other than hydrogen. Also preferrd are compounds where Z is 4-alkoxyphenyl, 4-aryloxyphenyl or heteroaryloxyphenyl.
In the above definitions, the term "heteroaryl" includes, but is not limited to pyrrole, furan, thiophene, pyridine, pyrimidine, pyridazine, pyrazine, triazole, pyrazole, imidazole, isothiazole, thiazole, isoxazole and oxazole. The term "5 to 7 membered saturated or unsaturated heterocyclic ring" includes, but is not limited to oxazolidine, thiazolidine, imidazolidine, tetrahydrofuran, tetrahydrohiophene, tetramethylene sulfone, dihydropyran, tetrahydropyran, piperidine, pyrrolidine, dioxane, morpholine, azepine and diazepine. The term "heteroaryl fused to a phenyl" includes, but is not limited to, benzoxazole, benzoisoxazole, indole, isoindole, benzothiophene, benzofuran, quinoline, quinazoline, quinoxaline, benzotriazole, benzimidazole, benzthiazole, benzopyrazole and isoquinoline.
The following compounds (1-10) which may be used in preparing invention compounds are known and references are given hereinbelow. ##STR7## Compound 1: a) Meyer, Michael D.; Altenbach, Robert J.; Basha, Fatima Z.; Carroll, William A.; Drizin, Irene; Elmore, Steven W.; Kerwin, Jr James F.; Lebold, Suzanne A.; Lee, Edmund L.; Sippy, Kevin B.; Tietje, Karin R.; Wendt, Michael D. Tricyclic substituted hexahydrobenz e!isoindole alpha-1 adrenergic antagonists. U.S. Pat. No. 5,597,823. CAN 126:199575.
b) Meyer, Michael D.; Altenbach, Robert J.; Basha, Fatima Z.; Carroll, William A.; Drizin, Irene; Kerwin, James F., Jr.; Lebold, Suzanne A.; Lee, Edmund L.; Elmore, Steven W.; et al. Preparation of tricyclic substituted benz e!isoindoles as a1 adrenergic antagonists. PCT Int. Appl WO 9622992 A1 CAN 125:221858.
Compound 2:
Troll, Theodor, Schmid, Klaus. Preparation and reactions of a 2H-pyrrolo 3,4-b!pyridine and a 2H-pyrrolo 3,4-b!pyrazine. J. Heterocycl. Chem. (1986), 23(6), 1641-4.
Compound 3:
Meyer, Michael D.; Altenbach, Robert J.; Basha, Fatima Z.; Carroll, William A.; Drizin, Irene; Elmore, Steven W.; Kerwin, Jr James F.; lebold, Suzanne A.; Lee, Edmund L.; Sippy, Kevin B.; Tietje, Karin R.; Wendt, Michael D. Tricyclic substituted hexahydrobenz e!isoindole alpha-1 adrenergic antagonists. U.S. Pat. No. 5,597,823. CAN 126:199575.
Compond 4:
a) Meyer, Michael D.; Altenbach, Robert J.; Basha, Fatima Z.; Carroll, William A.; Drizin, Irene; Elmore, Steven W.; Kerwin, Jr James F.; Lebold, Suzanne A.; Lee, Edmund L.; Sippy, Kevin B.; Tietje, Karin R.; Wendt, Michael D. Tricyclic substituted hexahydrobenz e!isoindole alpha-1 adrenergic antagonists. U.S. Pat. No. 5,597,823. CAN 126:199575.
b) Meyer, Michael D.; Altenbach, Robert J.; Basha, Fatima Z.; Carroll, William A.; Drizin, Irene; Kerwin, James F., Jr.; Lebold, Suzanne A.; Lee, Edmund L.; Elmore, Steven W.; et al. Preparation of tricyclic substituted benz e!isoindoles as a1 adrenergic antagonists. PCT Int. Appl. WO 9622992 A1 CAN 125:221858.
Compound 5:
Geach, Neil; Hawkins, David William; Pearson, Christopher John; Smith, Philip Henry Gaunt; White, Nicolas. Preparation of isoxazoles as herbicides. Eur. Pat. Appl. EP 636622 A1 CAN 122:290845.
Compound 6:
Kotovskaya, S. K.; Mokrushina, G. A.; Suetina, T. A.; Chupakhin, O. N.; Zinchenko, E. Ya.; Lesovaya, Z. I.; Mezentsev, A. S.; Chernyshov, A. I.; Samoilova, L. N. Benzimidazolyl derivatives of penicillin and cephalosporin: synthesis and antimicrobial activity. Khim.-Farm. Zh. (1989), 23(8), 952-6.
Compound 7:
Wagner, Klaus. Bactericidal and fungicidal 4chlorobenzothiazoles. Ger. Offen. DE 2136924 CAN 78:111293.
Compound 8:
Eggensperger, Heinz; Diehl, Karl H.; Kloss, Wilfried. 2-Hydroxy-4-alkoxybenzophenones. Ger. DE 1768599 711223. CAN 76:85557.
Compound 9:
Lichtenthaler, Frieder W.; Moser, Alfred. Nucleosides. 44. Benzo-separated pyrazolopyrimidines: expeditious syntheses of 3,4-g!- and 3,4-h!-linked pyrazoloquinazolinones. Tetrahedron Lett. (1981), 22(44), 4397-400.
Compound 10:
Terpstra, Jan W.; Van Leusen, Albert M. A new synthesis of benzo b!thiophenes and benzo c!thiophenes by annulation of disubstituted thiophenes. J. Org. Chem. (1986), 51(2), 230-8.
The compounds of this invention are shown to inhibit the enzymes MMP-1, MMP-9, MMP-13 and TNF-α converting enzyme (TACE) and inhibit cartilage weight loss and collegen content loss in-vivo are therefore useful in the treatment of arthritis, tumor metastasis, tissue ulceration, abnormal wound healing, periodontal disease, bone disease and HIV infection.
DETAILED DESCRIPTION OF THE INVENTION
The invention compounds are prepared using conventional techniques known to those skilled in the art of organic synthesis. The following scheme (Scheme I) illustrtes the general reaction sequence employed. For purposes of illustration only, wherein the group A shown is a phenyl, methyl anthranilate is reacted with p-methoxybenzenesulfonyl chloride to provide the requisite N-aryl sulfonamido-ester which is then alkylated to provide the N,N-disubstituted sulfonamide and subsequently converted into the corresponding hydroxamic acid in two further steps. ##STR8##
Basic salts of the hydroxamic acids can be formed with pharmaceutically acceptable alkli-forming metal cations such as lithium, sodium, potassium, calcium and aluminum. Acid addition salts can be formed when a substitutent contains a basic amino group using a pharmaceutically acceptable inorganic or organic acid such as hydrochloric, hydrobromic, phosphoric, sulfuric, acetic, benzoic, succinic, lactic, malic, maleic, fumaric or methanesulfonic acids.
Where the requisite anthranilic acid is not available, certain invention compounds are prepared by various procedures as shown in the following schemes. In some of the schemes, cerain conversions are not detailed but are understood to incorporate reactions denoted in a previous scheme. In certain reaction sequences a substituent R is not further identified by a number, but the identification of the substituent can readily be ascertained those skilled in the art by referring to the definitions of the various substituents in the generic formula above.
Scheme II below shows the synthetic route used to prepare the 3-trifluoromethyl compound of Example 125 via displacement of an ortho-fluorobenzonitrile. ##STR9##
Synthesis of 3- and 5-aryl and heteroaryl analogs was accomplished following the procedures shown in Schemes III and IV. In both schemes the aryl/heteroaryl group may be appended through the use of Stille or Suzuki palladium catalyzed coupling reactions. As shown in Scheme IV, the palladium catalyzed Stille or Suzuki couplings at the 5-position of the antanilic acid ring can be done before or after the alkylation of the sulfonamide nitrogen. ##STR10##
As shown in Scheme V, a Stille coupling of the 5-bromoaryl derivative, prepared as in Scheme IV, with a vinyl stannane provides access to the 5-substituted anthranilic acids bearing a wide variety of functionality including, but not limited to alkenes, allkes, hydroxamic acids, alcohols, halogens and amines. All of the ester derivatives shown in the Scheme may then be converted into the requisite hydroxamic acids. ##STR11##
The 5-position of the anthranilic acid ring can also be functionalized through the use of padium caalyzed Heck reactions, as shown in Scheme VI. Thus, reaction of the 5-bromo aryl derivative, prepared as in Scheme IV, with an acrylamide, acrylic acid or acrylic ester provides the 5-cinnamate derivatives, which may then be manipulated and converted into the aryl-hydroxamic acids by known procedures. These cinnarates may also be hydrogenated to give the phenethyl derivatives prior to conversion into the aryl-hydroxamic acids. A variety of substituents are tolerated on the anthranilic acid ring for these transformations and the scheme is presented solely for illustrative purposes. ##STR12##
An additional route to anthrnilic acid derivatives substituted at the 5-position, via palladium catalyzed couplings of the aryl halide with alkynes, is shown in Scheme VII. Again, conversion of the aryl esters into the hydroxamates is not shown. ##STR13##
Schemes VIII and IX illustrate routes to anthanilic acid derivatives bearing amine-containing functionality at the 3-position of the anthanilic acid ring. The intiate benzylic bromides can also be diplaced with malonte anion or other carbon-based nucleophiles. The 5-substituent of the anthranilate may be manipulated before or after the amino group is added to the molecule. ##STR14##
Scheme X shows the route used for the synthesis of 3,6-disubstituted anthranilic acid derivatives. Thus, the ester is converted into the hydroxamic acid by reduction to the alcohol followed by stepwise oxidation to the aldehyde and then the carboxylic acid. The carboxylic acid is then transforred into the hydroxamic acid by the usual procedures. ##STR15##
Schemnes XI and XII illustrate two methods for incorporating amino groups into the substituent attached to the sulfonamide nitrogen of the compounds of the invention. Thus, in Scheme XI the NH-sulfonamide is alkylated with propargyl bromide to provide the propargyl sulfonamide. This alkyne is reacted with paraformaldehyde in the presence of a lopimr or secondary amine and cuprous chloride to give the propargyl amine which is converted, as before, to the desired hydroxamnic acid. ##STR16##
In Scheme XII, selective hydrolysis of the ester of the p-carboethoxybenzyl sulfonamide group provides a mono-carboxylic acid. This acid may be converted into an amide (not shown), followed by conversion of the anthranilate into the corresponding hydroxamate, or reduced to the corresponding alcohol with diborane. The alcohol may be converted into the analogous amine via the benzylic bromide, followed by conversion of the anthranilate into the corresponding hydroxamate. ##STR17##
Amine substituents on the anthranilic acid are also available via the 3-nitro anthranilate derivative, as shown in Scheme XIII. The R 7 CH 2 -- group is added after the nitration reaction. ##STR18##
Palladium catalyzed couplings of the aryl bromides with the desired amines, as shown in Scheme XIV, can also be used to incorporate amnino groups into the anthranilate ring. When R7 in Scheme XIV is a bromoaryl group, this methodology may also be used to generate the analogous aminoaryl derivative. ##STR19##
The manipulation of the 3-carboxaldehyde substituent, prepared as shown in Scheme VIII, to append alcohols, ethers and esters at the 3-position of the anthranilic acids is shown in Scheme XV. The carboxylic acid product of the sodium chlorite/sulfamic acid oxidation shown in this scheme may also be used to synthesize carboxamides. The methods illustrated here are applicable to substituents at any position of the anthranilate. ##STR20## Scheme XVI shows the route used to prepare 3-alkoxy and substituted alkoxy compounds (Examples 34, 54-60, 101, 174) ##STR21##
Scheme XVII shows the route used to prepare benzoic acid ester intermediates of the invention compounds where R 7 -N-A forms a non-aromatic heterocyclic ring. ##STR22##
Methods for synthesizing variations of substituents on the sulfonyl aryl group are shown in Schemes XVIII through XXI. As shown in Scheme XVIII, biaryl sulfonyl groups are synthesized by Suzuki couplings on a bromo-substituted benzene sulfonamide. The starting bromo-substituted benzene sulfonamide is synthesized from the commercially available bromobenzenesulfonyl chloride and the anthranilate ester. ##STR23##
Methods for synthesizing sulfonyl aryl ethers are shown in Schemes XIX through XXI. In Scheme XIX biaryl ethers, or aryl heteroaryl ethers, are synthesized starting from the known sulfonyl chlorides (see for example: Zook SE; Dagnino, R; Deason, ME, Bender, SL; Melnick, MJ WO 97/20824). ##STR24##
Alternatively, the biaryl ethers may be prepared from the corresponding boronic acids or via the sulfonyl phenols as shown in Scheme XX. ##STR25##
Aryl ethers may also be prepared via displacement of the fluorine from a para-fluorobenzene sulfonamide, as shown in Scheme XXI. Aryl or alkyl ethers may be prepared in this manner. ##STR26##
The procedure for the solid-phase synthesis of the compounds of the invention is illustrated in Scheme XXII. Thus, reaction of the resin-linked hydroxylamine, 4, with the pentafluorophenyl ester, 6, gives the resin-linked hydroxamic acid, 7. Sulfonylation of this compound followed by Mitsunobu type alkylation of the sulfonamide then gives compound 9 which is next cleaved from the resin by treatment with trifluoroacetic acid. ##STR27##
The following specific examples are included for illustrative purposes and are not to be construed as limiting to this disclosure in any way. Other procedures useful for the preparation of the compounds of this invention will be apparent to those skilled in the art of synthetic organic chemistry.
EXAMPLE 1
2-(4-Methoxy-benzenesulfonylamino)-benzoic acid methyl ester
To a solution of 2.00 g (0.013 mol) of methyl anthilt dissolved in 20 mL of chloroform was added 3.2 mL (0.039 mol) of pyridine followed by 2.733 g (0.013 mol) of p-methoxybenzenesulfonyl chloride. The reacon mixture was stirred at room temperature for 5 h and then washed with 3N HCl and water. The organics were then dried over Na 2 SO 4 , filtered and concentrated in vacuo. The resulting white solid was washed with ether and dried in vacuo to provide 3.7 g (87%) of the desired sulfonamide. CI Mass Spec: 322 (M+H).
EXAMPLE 2
3-Chloro-2-(4-methoxybenzenesulfonylamino)-benzoic acid methyl ester
In the same manner as described in Example 1, 4.07 g (0.022 mol) of methyl-3-chloro-anthranilate provided 0.932 g (12%) of the desired sulfonamide as a white solid.
EXAMPLE 3
2-(4-Methoxy-benzenesulfonylamino)-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 1, 6.24 g (0.038 mol) of methyl-3-methyl-anthranilate provided 6.21 g (49%) of the desired sulfonamide as a white solid. Electrospray Mass Spec 336.2 (M+H).
EXAMPLE 4
2-(4-Methoxy-benzenesulfonylamino)-4-methyl-benzoic acid
To a room temperature solution of 2-amino-4-methyl benzoic acid (1.93 g, 12.8 mmol) in 20 ml of dioxane:H 2 O (1:1) containing triethylamine (2.68 ml, 19.2 mmol), was added 4-methoxybenzenesulfonyl chloride (2.91 g, 14.1 mmol). The mixture was stired at rt for 18 hr. The resulting mixture was diluted with methylene chloride, washed with 1N HCl, H 2 O, brine, dried and concentrated. The crude liquid was triturated with 16 ml of EtOAc: hexane (1:3) to afford 2.358 g of the desired product as a white solid (57%). Electrospray Mass Spec 322 (M+H).
EXAMPLE 5
2-(4-Methoxy-benzenesulfonylamino)-6-methyl-benzoic acid
In the same manner as described in Example 4, 1.93 g of 2-amino-6-methylbenzoic acid (12.8 mmol) gave 2.24 g (55%) of the desired sulfonamide product as a white solid after silica gel chromatography (2% MeOH-0.1% AcOH in CH 2 Cl 2 ). Electrospray Mass Spec: 322 (M+H).
EXAMPLE 6
2-(4-Methoxy-benzenesulfonylamino)-3-methyl-benzoic acid
In the same manner as described in Example 4, 1.93 g of 2-amino-3-methylbenzoic acid (12.8 mmol) gave 2.07 g (50%) of the desired sulfonamide as a white solid after trituration with EtOAc: hexane (1:4). EI Spec: 321 (M + ).
EXAMPLE 7
2-(4-Methoxy-benzenesulfonylamino)-5-methyl-benzoic acid
In the same manner as described in Example 4, 1.93 g of 2-amino-5-methylbenzoic acid (12.8 mmol) gave 2.498 g (61%) of the desired sulfonamide as a white solid after trituration with CH 2 Cl 2 : hexane (1:2). Electrospray Mass Spec: 320 (M-H).
EXAMPLE 8
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-benzoic acid benzyl and methyl esters
To a solution of 1.00 g (3.12 mmol) of the product of Example 1 in 45 mL of DMF was added 0.37 mL (3.12 mmol) of benzyl bromide and 3.23 g (0.023 mol) of potassium carbonate. The reaction was heated to reflux for 24 h and an additional 1.11 mL of benzyl bromide was added and the reaction mixture was heated to reflux for another 48 h, then cooled to room temperature and diluted with 400 mL of water. The resulting mixture was extracted with ether and the combined organic layers were then washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel eluting with EtOAc/Hex (1:10) to provide 0.60 g (40%) of the benzyl ester (CI Mass Spec: 488 (M+H)), which gave white crystals on trituration with ether, and 0.57 g (44%) of the methyl ester (CI Mass Spec: 412 (M+H)).
EXAMPLE 9
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-chloro-benzoic acid methyl ester
To a solution of 0.90 g (2.532 mmol) of the product of Example 2 in 10 mL of DMF was added 0.127 g (3.165 mmol) of 60% sodium hydride. The resulting mixture was stirred for 30 min at room temperatue and then 0.38 mL (3.165 mmol) of benzyl bromide was added. This reaction mixture was stirred overnight at room temperature, poured into water and then extracted with ether. The combined organics were washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo to provide a white solid which was recrystallized from EtOAc/liexanes to provide 0.44 g (39%) of the desired product as white crystals. CI Mass Spec: 446 (M+H).
EXAMPLE 10
5-Bromo-2-(4-methoxy-benzenesulfonylamino)-3-methyl-benzoic acid methyl ester
To a solution of 1.00 g (2.985 mmol) of the product of Example 3 in 100 mL of CHCl 3 was added 0.531 g (2.985 mmol) of N-bromosuccinimide and 0.025 g of AIBN. The resulting mixture was heated to reflux for 18 h and then an additional 0.411 g of NBS and 0.013 g of AIBN were added to the reaction. After refluxing the reaction for another 5 h the reaction mixture was cooled to room temperature, washed with sodium sulfite solution and water, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was triturated with ether-hexanes to provide 0.62 g (50%) of the desired product as a white solid. EI Mass Spec 413 (M + ).
EXAMPLE 11
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-bromo-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 9, 0.463 g (1.118 mmol) of the product of Example 10 provided 0.514 g (91%) of the desired product as a colorless oil after chromatography on silica gel eluting with EtOAc/Hexanes (1:10). CI Mass Spec: 504 (M+H).
EXAMPLE 12
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-4-methyl-benzoic acid benzyl ester
To a solution of 1.82 g (5.66 mmol) of the product of Example 4 in 20 ml DMF, was added NaH (60% suspension in oil, 498 mg, (12.5 mmol). The resulting mixture was stired for 15 minutes and benzyl bromide (4.84 g, 0.028 mol) was then added. The mixture was heated to 80-84° with stirnng for 18 hr under N 2 . The motion was then cooled to room temperature, diluted with ether, washed with H 2 O and brine, dried over MgSO 4 and concentrated in vacuo. The residue was triturated with EtOAc to afford 2.2 g (77%) of the desired product as a white solid. Electrospray Mass Spec: 502 (M+H).
EXAMPLE 13
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-6-methyl-benzoic acid benzyl ester
In the same manner as described in Example 12, 1.45 g (4.5 mmol) of the product of Example 5 gave 1.18 g (52%) of the desired product as a white solid after silica gel chromatography eluting with EtOAc:hexane (1:9). Electrospray Mass Spec: 502 (M+H).
EXAMPLE 14
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-methyl-benzoic acid benzyl ester
In the same manner as described in Example 12, 1.6 g (5.00 mmol) of the product of Example 6 gave 1.269 g (50%) of the desired product as a white solid after silica gel chromatography eluting with EtOAc:Hexane (1:9). CI Mass Spec: 502 (M+H).
EXAMPLE 15
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-methyl-benzoic acid benzyl ester
In the same manner as described in Example 12, 1.821 g (5.66 mmol) of the product of Example 7 gave 2.13 g (75%) of the desired product as a white solid after silica gel chromatogrrphy eluting with EtOAc:Hexane (1:5). Electrospray Mass Spec: 502 (M+H).
EXAMPLE 16
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-benzoic acid
To a mixture of 0.60 g (0.123 mmol) of benzyl ester and 0.57 g (0.139 mmol) of methyl ester of Example 8 dissolved in 30 mL of methanol and30 mL of THF was added 30 mL of 1N NaOH solution. The reaction mixture was stirred at room temperature for 48 h and the organics were removed in vacuo. The resulting mixture was acidified with 10% HCl and extracted with EtOAc. The combined organics were washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The resulting residue was triturated with hexanes and filtered to provide 0.87 g (84%) of the desired carboxylic acid as a white solid. CI Mass Spec: 398 (M+H).
EXAMPLE 17
2- Benzyl-(4-metboxy-benzenesulfonyl)-amino!-3-chloro-benzoic acid
In the same manner as described in Example 16, 0.404 g (0.907 mmol) of the product of Example 9 provided 0.327 g (84%) of the desired carboxylic acid as a white solid. Electrospray Mass Spec 432 (M+H).
EXAMPLE 18
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-bromo-3-methyl-benzoic acid
To a solution of 0.444 g (0.88 lmmol) of the product of Example 11 in 20 mL of MeOH/THF (1:1) was added 9.3 mL 1N NaOH and the mixture heated at reflux for 18 h. The mixture was cooled to room temperature and the organic removed in vacuo. The remaining solution was acidified with 10% HCl and extracted with EtOAc. The extract was washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The residue provided 0.364 g (84%) of the desired carboxylic acid as a white solid after trturation with ether. CI Mass Spec: 490 (M+H).
EXAMPLE 19
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-4-methyl-benzoic acid
To a solution of the product of Example 12 in 30 mL of methanol was added 7.5 mL (0.038 mol) of 5N sodium hydroxide solution and the resulting mixture was heated to reflux for 66 h. The reaction was then cooled to room tempeature and the organics were removed in vacuo. The resulting mixture was acidified with 10% HCl and extracted with EtOAc. The combined organics were washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The resulting residue was triturated with ether and filtered to provide 0.984 g (79%) of the desired carboxylic acid as a white solid. Electospray Mass Spec: 427 (M+H).
EXAMPLE 20
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-6-methyl-benzoic acid
In the same manner as described in Example 19, 1.043 g (2.08 mmol) of the product of Example 13 provided 0.547 g (64%) of the desired carboxylic acid as a white solid after recrystallization from EtOAc/Hexanes. Electrospray Mass Spec: 412 (M+H).
EXAMPLE 21
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-methyl-benzoic acid
In the same manner as described in Example 19, 0.935 g (1.864 mmol) of the product of Example 14 provided 0.551 g (72%) of the desired carboxylic acid as a white solid after trituration with hexanes. Electrospray Mass Spec: 412 (M+H).
EXAMPLE 22
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-methyl-benzoic acid
In the same manner as described in Example 19, 1.931 g (3.85 mmol) of the product of Example 15 provided 1.19 g (70%) of the desired carboxylic acid as a white solid after trituration with CH 2 Cl 2 /hexanes (2:1). Electrospray Mass Spec: 412 (M+H).
EXAMPLE 23
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-benzamide
To a solution of 0.50 g (1.26 mmol) of the product of Example 16 in 12.5 mL of dichloromethane was added 0.095 mL of DMF followed by 0.22 mL of oxalyl chloride and the resulting reaction mixture was stirred at room temperature for 1 h.
In a separate flask, 1.05 mL (7.55 mmol) of triethylamine was added to a 0° C. mixture of 0.35 g (5.04 mmol) of hydroxylamine hydrochloride in 5.5 mL of THF and 1.4 mL of water. After this mixture had stirred for 15 min at 0° C., the acid chloride solution was added to it in one portion and the resulting solution was allowed to warm to room temperature with stirring overnight. The reaction mixture was then acidified to pH3 with 10% HCI and extracted with EtOAc. The combined organic layers were dried over Na 2 SO 4 , filtered and concentrated in vacuo. The crude residue was triturated with ether to provide 0.43 g (83%) of the desired hydroxamic acid as a white solid. CI Mass Spec: 413 (M+H).
EXAMPLE 24
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-chloro-N-hydroxy-benzamide
In the same manner as described in Example 23, 0.280 g (0.649 mmol) of the product of Example 12 gave 0.161 g (56%) of the desired hydroxamic acid as a white solid. Electrospray Mass Spec: 446 (M+H).
EXAMPLE 25
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-bromo-N-hydroxy-3-methyl-benzamide
In the same manner as described in Example 23, 0.303 g (0.618 mmol) of the product of Example 18 gave 0.164 g (53%) of the desired hydroxamic acid as a white solid. Electrospray Mass Spec: 505 (M+H).
EXAMPLE 26
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-4-methyl-benzamide
In the same manner as described in Example 23, 1.20 g (2.91 mmol) of the product of Example 19 gave 0.984 g (79%) of the desired hydroxamic acid as a white solid after trituration with ether. Electrospray Mass Spec: 427 (M+H).
EXAMPLE 27
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-6-methyl-benzamide
In the same manner as described in Example 23, 0.537 g (1.30mmol) of the product of Example 20 gave 0.443 g (80%) of the desired hydroxamic acid as a white solid after trituration with CH 2 Cl 2 /Hexanes (1:4). Electrospray Mass Spec: 427 (M+H).
EXAMPLE 28
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-methyl-benzamide
In the same manner as described in Example 23, 0.398 g (0.967 mmol) of the product of Example 21 gave 0.348 g (84%) of the desired hydroxamic acid as a white solid after trituation with CH 2 Cl 2 /Hexanes (1:4). Electrospray Mass Spec: 427 (M+H).
EXAMPLE 29
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-5-methyl-benzamide
In the same manner as described in Example 23, 1.00 g (2.43 mmol) of the product of Example 22 gave 0.761 g (73%) of the desired hydroxamic acid as a white solid after trituration with CH 2 Cl 2 /Hexanes (1:4). Electrospray Mass Spec: 427 (M+H).
EXAMPLE 30
2-Amino-3-hydroxy-benzoic acid methyl ester
To a solution of 1.0 g (6.53 mmol) of 3-hydroxyanthranilic acid in 15 mL of methanol was added 5.0 mL of BF 3 -methanol complex and the resulting solution was heated to reflux for 24 h. After cooling to room temperatue the reaction mixture was poured into saturated sodium carbonate solution and then extracted with ether. The combined organics were washed with water and brine, dried over sodium sulfate, filtered and concentrated in vacuo to provide 0.90 g (83%) of the desired product as a brown solid. Electrospray Mass Spec: 167.8 (M+H)+
EXAMPLE 31
3-Hydroxy-2-(4-methoxy-benzenesulfonylamino)-benzoic acid methyl ester
To a solution of 0.748 g (4.48 mmol) of the product of Example 30 in 10.0 mL of pyridine was added 0.928 g (4.48 mmol) of p-methoxybenzenesulfonyl chloride. The reaction mixture was stirred for 24 h at room temperature and then diluted with chloroform and washed with 5% HCl solution and water. The organic layer was then dried over MgSO 4 , filtered and concentrated in vacuo. The residue was triturated with ether-hexanes and the resulting solid was filtered and dried to provide 0.86 g (57%) of the desired product as a tan solid. Electrospray Mass Spec: 338.2 (M+H)+
EXAMPLE 32
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-benzyloxy-benzoic acid methyl ester
In the same manner as described in Example 9, 0.50 g (1.17 mmol) of the product of Example 31 provided 0.60 g (100%) of the desired product as a colorless oil. Electrospray Mass Spec: 518.2 (M+H)+
EXAMPLE 33
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-benzyloxy-benzoic acid
In the same manner as descrbed in Example 18, 0.25 g (0.484 mmol) of the product of Example 32 provided 0.22 g (91%) of the desired product as a white solid. Electrospray Mass Spec: 504.2 (M+H)+
EXAMPLE 34
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-benzyloxy-N-hydroxy-benzamide
In the same manner as described in Example 23, 0.19 g (0.382 mmol) of the product of Example 33 provided 0.16 (81%) of the desired product as a white solid. Electrospray Mass Spec: 519.2 (M+H)+
EXAMPLE 35
3-(tert-Butyl-dimethyl-silanyloxy)-2-(4-methoxy-benzenesulfonylamino)-benzoic acid methyl ester
To a solution of 0.139 g (0.412 mmol) of the product of Example 31 in 2.0 mL of DMF was added 0.70 g (1.03 mmol) of imidazole and 0.075 g (0.495 mmol) of t-butyldimethylsilyl chloride. The reaction mixture was then srtied at room temperature for 3h and then diluted with 75 mL of ether. The resulting mixture was washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo to provide 0.179 g (96%) of the desired product as a white solid. Electrospray Mass Spec: 452.2 (M+H)+
EXAMPLE 36
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-(tert-butyl-dimethyl-silanyloxy)-benzoic acid methyl ester
In the same manner as described in Example 9, 0.114 g (0.253 mmol) of the product of Example 35 provided 0.088 (64%) of the desired product as a colorless oil. Electrospray Mass Spec: 542.3 (M+H)+
EXAMPLE 37
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-hydroxy-benzoic acid methyl ester
To a solution of 4.42 g (8.17 mmol) of the product of Example 36 in 50 mL of THF was added 16.3 mL (16.3 mmol) of a 1M solution of Bu 4 NF/THF. The reaction mixture was stirred at room tempeture for 0.5 h and then diluted with ether and washed with 5% HCl solution, water and brine. The resulting solution was dried over MgSO 4 , filtered and concentrated in vacuo. The residue was triturated with ether to provide 2.81 g (81%) of the desired product as a white solid. Electrospray Mass Spec: 428.3 (M+H)+
EXAMPLE 38
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-tert-butoxycarbonylmethoxy-benzoic acid methyl ester
To a solution of 0.40 g (0.94 mmol) of the product of Example 37 in 10 mL of DMF was added 0.047 g (1.171 mmol) of a 60% suspension of sodium hydride in minena oil. The resulting mixture was stirred at room temperature for 0.5 h and then 0.277 mL (1.873 mmol) of t-butylbromoacetate was added in one portion. Th reaction mixture was stirred for an additional 18 h and then diluted with ether, washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was triturated with ether-hexanes to provide 0.423 g (83%) of the desired product as a white solid. Electrospray Mass Spec: 524.3 (M+H)+
EXAMPLE 39
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-(2,2,2-trifluoro-ethoxy)-benzoic acid methyl ester
In the same manner as described in Example 38, 0.40 g (0.937 mmol) of the product of Example 37 and 0.185 mL (1.873 mmol) of 2-iodo-1,1,1-trifluoroethane provided 0.231 g (48%) of the desired product as a colorless oil. Electrospray Mass Spec: 510.3 (M+H)+
EXAMPLE 40
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-(2-methoxy-ethoxymethoxy)-benzoic acid methyl ester
In the same manner as described in Example 38, 0.40 g (0.937 mmol) of the product of Example 37 and 0.134 mL (1.171 mmol) of MEM-Cl provided 0.454 g (94%) of the desired product as a colorless oil. Electrospray Mass Spec: 516.2 (M+H)+
EXAMPLE 41
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-(4-methoxycarbonyl-benzyloxy)-benzoic acid methyl ester
In the same manner as described in Example 38, 0.275 g (0.644 mmol) of the product of Example 37 and 0.295 g (1.288 mmol) of methyl 4-(bromomethyl)benzoate provided 0.322 g (87%) of the desired product as a white solid. Electrospray Mass Spec: 576.2 (M+H)+
EXAMPLE 42
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-(3-ethoxycarbonyl-propoxy)-benzoic acid methyl ester
In the same manner as described in Example 38, 0.50 g (1.171 mmol) of the product of Example 37 and 0419 mL (2.927 mmol) of ethyl 4-bromobutyrate provided 0.530 g (84%) of the desired product as a colorless oil. Electrospray Mass Spec: 542.3 (M+H)+
EXAMPLE 43
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-(4-methoxycarbonyl-butoxy)-benzoic acid methyl ester
In the same manner as described in Example 38, 050 g (1.171 mmol) of the product of Example 37 and 0.419 mL (2.927 mmol) of methyl 5-bromovalerate provided 0.477 g (75%) of the desired product as a white solid. Electrospray Mass Spec: 542.3 (M+H)+
EXAMPLE 44
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-isopropoxy-benzoic acid methyl ester
To a solution of 0.20 g (0.468 mmol) of the product of Example 37 dissolved in 5.0 mL of DMF was added 0.26 mL (2.81 mmol) of 2-bromopropane and 1.16 g (8.43 mmol) of potassium carbonate. The reaction mixture was then heated to 80 degrees for 18 h, cooled to room temperature, diluted with ether and washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel eluting with EtOAc-Hexanes (1:3) to provide 0.198 g (90%) of the desired product as a colorless oil. Electrospray Mass Spec: 470.3 (M+H)+
EXAMPLE 45
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-(pyridin-3-ylmethoxy)-benzoic acid methyl ester
To a solution of 0.40 g (1.187 mmol) of the product of Example 31 dissolved in 5.0 mL of DMF was added 0.409 g (2.492 mmol) of 3-picolyl chloride hydrochloride and 1.03 g (7.477 mmol) of potassium carbonate. The reaction mixture was then stirred at room temperature for 18 h, diluted with water and extracted with ether. The organics were then extracted with 6N HCl solution and the aqueous acid layer was then basified with 6N NaOH solution and then extrrcted with ether. The resulting ether layer was dried over sodium sulfate, filtered and concentrated in vacuo to provide 0.34 g (55%) of the desired product as a brown oil. Electrospray Mass Spec: 520.2 (M+H)+
EXAMPLE 46
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-carboxymethoxy-benzoic acid
In the same manner as described in Example 18, 0.314 g (0.580 mmol) of the product of Example 38 provided 0.262 g (96%) of the desired product as a white solid. Electrospray Mass Spec: 472.1 (M+H)+
EXAMPLE 47
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-(2,2,2-trifluoroethoxy)-benzoic acid
In the same manner as described in Example 18, 0.20 (0.393 mmol) of the product of Example 39 provided 0.168 g (87%) of the desired product as a white solid. Electrospray Mass Spec: 496.1 (M+H)+
EXAMPLE 48
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-(2-methoxy-ethoxymethoxy)-benzoic acid
In the same manner as described in Example 18, 0.363 g (0.705 mmol) of the product of Example 40 provided 0.336 (95%) of the desired product as a white foam. Electrospray Mass Spec: 502.2 (M+H)+
EXAMPLE 49
benzyloxy)-benzoic acid
In the same manner as described in Example 18, 0.283 g (0.492 mmol) of the product of Example 41 provided 0.245 g (91%) of the desired product as a white solid. Electrospray Mass Spec: 548.1 (M+H)+
EXAMPLE 50
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-(3-carboxy-propoxy)-benzoic acid
In the same manner as described in Example 18, 0.363 g (0.671 mmol) of the product of Example 42 provided 0.260 g (78%) of the desired product as a white solid. Electrospray Mass Spec: 498.1 (M-H)-
EXAMPLE 51
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-(4-carboxy-butoxy)-benzoic acid
In the same manner as described in Example 18, 0.323 g (0.597 mmol) of the product of Example 43 provided 0.243 (79%) of the desired product as a white solid. Electrospray Mass Spec: 512.1 (M-H)-
EXAMPLE 52
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-isopropoxy-benzoic acid
In the same manner as described in Example 18, 0.348 g (0.742 mmol) of the product of Example 44 provided 0.284 g (84%) of the desired product as a white solid. Electrospray Mass Spec: 456.3 (M+H)+
EXAMPLE 53
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-(pyridin-3-ylmethoxy)-benzoic acid
To a solution of 0.311 g (0.599 mmol) of the product of Example 45 in 6.0 mL of THF-MeOH (1:1) was added 0.050 g (1.197 mmol) of lithium hydroxide monohydrate. The reaction mix was heated to reflux for 24 h and then concentrated in vacuo. The residue was washed with THF and filtered. The filtrate was concentrated in vacuo to provide 0.277 g (91%) of the lithium salt of the title compound as a brown foam. Electrospray Mass Spec: 506.2 (M+H)+
EXAMPLE 54
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3hydroxycarbamoylmethoxy-benzamide
In the same manner as described in Example 23, 0.110 g (0.234 mmol) of the product of Example 46 provided 0.085 g (75%) of the desired product as a white solid. Electrospray Mass Spec: 502.2 (M+H)+
EXAMPLE 55
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-(2,2,2-trifluoroethoxy)-benzamide
In the same manner as described in Example 23, 0.131 (0.265 mmol) of the product of Example 47 provided 0.092 g (68%) of the desired product as a white solid. Electrospray Mass Spec: 511.1 (M+H)+
EXAMPLE 56
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-(2-methoxy-ethoxymethoxy)-benzamide
In the same manner as described in Example 23, 0.296 (0.591 mmol) of the product of Example 48 provided 0.228 g (75%) of the desired product as a brown glass. Electrospray Mass Spec: 517.2 (M+H)+
EXAMPLE 57
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3- 4-(hydroxyaminocarbonyl)-benzyloxy!-N-hydroxy-benzamide
In the same manner as described in Exanple 23, 0.207 g (0.378 mmol) of the product of Example 49 provided 0.20 g (92%) of the desired product as a white solid. Electrospray Mass Spec: 576.0 (M-H)-
EXAMPLE 58
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-(3-hydroxycarbamoyl-propoxy)-benzamide
In the same manner as described in Example 23, 0.224 g (0.449 mmol) of the product of Example 50 provided 0. 195 g (82%) of the desired product as a white solid. Electrospray Mass Spec: 530.1 (M+H)+
EXAMPLE 59
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-(4-hydroxycarbamoyl-butoxy)-benzamide
In the same manner as described in Example 23, 0.20 g (0.390 mmol) of the product of Example 51 provided 0.208 g (98%) of the desired product as a tan solid. Electrospray Mass Spec: 544.1 (M+H)+
EXAMPLE 60
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-isopropoxy-benzamide
In the same manner as described in Example 23, 0.245 g (0.540 mmol) of the product of Example 52 provided 0.222 g (88%) of the desired product as a white solid. Electrospray Mass Spec: 471.2 (M+H)+
EXAMPLE 61
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzamide
To a solution of 0.65 mL (1.29 mmol) of a 2M solution of oxalyl chloride in CH 2 Cl 2 at 0° C. was added 0.10 mL (1.29 mmol) of DMF and the mixture was stirred at 0° C. for 15min, then let warm to room temperature and stired for an additional 1 h. A solution of 0.220 g (0.43 mmol) of the product of Example 53, in 1 mL of DMF, was then added to the reaction mixture and the reaction was stirred for 1 h at room temperature.
In a separate flask, 1.35 mL (9.675 mmol) of triethylamine was added to a 0° C. mixture of 0.448 g (6.45 mmol) of hydroxylamine hydrochloride in 6.8 mL of THF and 1.8 mL of water. After this mixture had stirred for 15 min at 0° C., the acid chloride solution was added to it in one portion and the resulting solution was allowed to warm to room tempature with stirring overnight. The reaction mixture next was diluted with CH 2 Cl 2 and washed with water and saturated sodium bicarbonate solution. The organic layer was dried over Na 2 SO 4 , filtered and concentrated in vacuo. The crude residue was tritrated with ether to provide 0.124 g (55%) of the desired hydroxamic acid as a white solid. Electrospray Mass Spec: 521.2 (M+H)+.
EXAMPLE 62
2-(4-Methoxy-benzenesulfonylamino)-3,5-dimethyl-benzoic acid methyl ester
In the same manner as described in Example 31, 7.00 g (0.039 mol) of methyl 3,5-dimethylanthranilate provided 11.5 g (84%) of the desired product as a white solid. Electrospray Mass Spec: 350.3 (M+H)+.
EXAMPLE 63
2-(4-Fluoro-benzenesulfonylamino)-3,5-dimethyl-benzoic acid methyl ester
In the same manner as described in Example 31, 2.00 g (0.011 mol) of methyl 2,5-dimethylanthranilic acid and 2.17 g (0.011 mol) of 4-fluorobenzenesulfonyl chloride provided 3.09 g (82%) of the desired product as a white solid. Electrospray Mass Spec: 338.3 (M+H)+.
EXAMPLE 64
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid methyl ester
In the same manner as described in Example 9, 1.00 g (0.2.865 mmol) of the product of Example 62 provided 1.065 g (85%) of the desired product as a white solid. Electrospray Mass Spec: 440.3 (M+H)+.
EXAMPLE 65
2- Benzyl-(4-fluoro-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid methyl ester
In the same manner as described in Example 9, 1.00 g (0.2.865 mmol) of the product of Example 63 provided 1.084 g (85%) of the desired product as a white solid. Electrospray Mass Spec: 428.3 (M+H)+.
EXAMPLE 66
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid
In the same manner as described in Example 18, 0.94 g (2.141 mmol) of the product of Example 64 provided 0.827 g (91%) of the desired product as a white solid. Electrospray Mass Spec: 426.3 (M+H)+.
EXAMPLE 67
2- Benzyl-(4-fluoro-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid
In the same manner as described in Example 9, 0.963 g (2.255 mmol) of the product of Example 65 provided 0.486 g (52%) of the desired product as a white solid. Electrospray Mass Spec: 414.3 (M+H)+.
EXAMPLE 68
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3,5-dimethyl-benzamide
In the same manner as described in Example 23, 0.683 g (1.607 mmol) of the product of Example 66 provided 0.436 g (62%) of the desired product as a white solid. Electrospray Mass Spec: 441.3 (M+H)+.
EXAMPLE 69
2- Benzyl-(4-fluoro-benzenesulfonyl)-amino!-N-hydroxy-3,5-dimethyl-benzamide
In the same manner as described in Example 23, 0.423 g (1.024 mmol) of the product of Example 67 provided 0.364 g (83%) of the desired product as a white solid. Electrospray Mass Spec: 429.3 (M+H)+.
EXAMPLE 70
2- Benzyl-(4-butoxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid butyl ester
To a solution of the product of Example 65 in 10 mL of DMF was added 0.429 mL (4.684 mmol) of n-butanol and 0.187 g (4.684 mmol) of 60% sodium hydride. The reaction mixture was stired for 18 h at room temperature and the quenched with 5% HCl solution. The resulting mixture was extracted with ether and the combined organics were washed with water, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica eluting with EtOAc-Hexanes (1:10) to provide 0. 134 g (24%) of the desired product as a red oil. Electrospray Mass Spec: 524.4 (M+H)+.
EXAMPLE 71
2- Benzyl-(4-butoxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid
In the same manner as described in Example 18, 0.134 g (0.256 mmol) of the product of Example 70 provided 0.115 g (97%) of the desired product as a white solid. Electrospray Mass Spec: 468.3 (M+H)+.
EXAMPLE 72
2- Benzyl-(4-butoxy-benzenesulfonyl)-amino!-N-hydroxy-3,5-dimethyl-benzamide
In the same manner as described in Example 23, 0.139 g (0.298 mmol) of the product of Example 71 provided 0.105 g (73%) of the desired product as a yellow foam. Electrospray Mass Spec: 483.3 (M+H)+.
EXAMPLE 73
2- Benzyl-(4-benzyloxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid
To a solution of 0.50 g (1.171 mmol) of the product of Example 65 in 10 mL of DMF was added 0.485 mL (4.684 mmol) of benzyl alcohol and 0.187 g (4.684 mmol) of 60% sodium hydride. The eaction mixture was stirred for 18 h at room temperature and the quenched with 5% HCl solution. The resulting mixture was extracted with ether and the combined organics were washed with water, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was dissolved 10 mL of MeOH-THF (1:1) and 4.7 mL of 1N sodium hydroxide solution was added. The resulting mixture was heated to reflux for 18 h and then cooled to room temperature, acidified with 5% HCl and extracted with EtOAc. The combined organics were washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. Triturion of the residue with edter provided 0.432 g (74%) of the desired product as a white solid. Electrospray Mass Spec: 502.3 (M+H)+.
EXAMPLE 74
2- Benzyl-(4-benzyloxy-benzenesulfonyl)-amino!-N-hydroxy-3,5-dimethyl-benzamide
In the same manner as described in Example 23, 0.366 (0.731 mmol) of the product of Example 73 provided 0.347 g (92%) of the desired product as a white solid. Electrospray Mass Spec: 517.2 (M+H)+.
EXAMPLE 75
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-hex-1-ynyl-3-methyl-benzoic acid methyl ester
To a solution of 0.324 g (0.643 mmol) of the product of Example 11 in 2.0 mL of DMF and 2.0 mL of triethylamine was added 0.088 mL (0.771 mmol) of 1-hexyne, 9 mg (0.013 mmol) of bis(triphenylphosphine)palladium(II)dichloride and 1.2 mg of copper(I)iodide. The reaction mixture was then heated to 65 degrees for 5 h and an additional 0.22 mL of 1-hexyne was added to the reaction. The motion was then heated to zeflux for 6 h and then cooled to room tempemaure and diluted with ether. The organics were washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica eluting with EtOAc-Hex (1:10) to provide 0.198 g (61%) of the desired product as a yellow oil. Electrospray Mass Spec: 506.3 (M+H)+.
EXAMPLE 76
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-hex-1-ynyl-3-methyl-benzoic acid
In the same manner as described in Example 18, 0.165 g (0.327 mmol) of the product of Example 75 provided 0.123 g (77%) of the desired product as a tan solid. Electrospray Mass Spec: 492.2 (M+H)+.
EXAMPLE 77
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-hex-1-ynyl-N-hydroxy-3-methyl-benzamide
In the same manner as described in Example 23, 0.115 g (0.234 mmol) of the product of Example 76 provided 0.097 g (82%) of the desired product as a tan foam. Electrospray Mass Spec: 507.3 (M+H)+.
EXAMPLE 78
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-ethynyl-3-methyl-benzoic acid methyl ester
To a solution of 0.277 g (0.50 mmol) of the product of Example 11 in 2.0 mL of DMF and 2.0 mL of triethylamine was added 0.39 mL (0.2.748 mmol) of trimetylsilyl acetylene, 19 mg (0.027 mmol) of bis(triphenylphosphine)palladium(II)dichloride and 2.6 mg of copper(I)iodide. The reaction mixture was then heated to 65 degrees for 2 h and then cooled to room temperature and diluted with ether. The organics were washed with 5% Hcl solution, water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was dissolved in 5 mL of THF, 1 mL of 1M tetrbutylammonium fluoride-THF solution was added and the reaction was stirred at room temperatue for 1 h, then diluted with ether, washed with 5% HCl solution, water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica eluting with EtOAc-Hex (1:10) to provide 0.197 g (80%) of the desired product as a white foam. Electrospray Mass Spec: 450.3 (M+H)+.
EXAMPLE 79
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-ethynyl-3-methyl-benzoic acid
In the same manner as described in Example 18, 0.177 g (0.394 mmol) of the product of Example 78 provided 0.161 g (94%) of the desired product as a tan solid. Electrospray Mass Spec: 436.2 (M+H)+.
EXAMPLE 80
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-ethynyl-N-hydroxy-3-methyl-benzamide
In the same manner as described in Example 23, 0.136 g (0.313 mmol) of the product of Example 79 provided 0.116 g (82%) of the desired product as a tan foam. Electrospray Mass Spec: 451.3 (M+H)+.
EXAMPLE 81
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid methyl ester
To a solution of 1.00 g (2.985 mmol) of the product of Example 3 in 7.5 mL of DMF was added 0.514 g (3.134 mmol) of 3-picolyl chloride hydrochloride and 1.30 g (9.50 mmol) of potassium carbonate. The rection was stirred for 18 h at room temre and then an additional 0.051 g of 3-picolyl chloride hydrochloride and 0.130 g of potassium carbonate was added and the reaction was steeed for 18 h at room temperature. The reaction was then diluted with water and extracted with ether. The combined organic layers were extrated with 6N HCl solution and the aqueous acid layer was then basified with 6N NaOH solution and then extracted with ether. The resulting ether layer was dried over sodium sulfate, filtered and concentrated in vacuo. Trituration of the residue with ether provided 1.058 g (83%) of the desired product as a white solid. Electrospray Mass Spec: 427.3 (M+H)+.
EXAMPLE 82
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid
To a solution of 0.924 g (2.169 mmol) of the product of Example 81 in 10 mL of THF-water (1:1) was added 0.091 g of lithium hydroxide monohydrate. The reaction mixture was heated to reflux for 48 h then cooled to room temeratue and washed with ether. The aqueous layer was then concentrated in vacuo to provide 0.894 g (100%) of the lithium salt of the tide compound as a white solid. Electrospray Mass Spec: 413.2 (M+H)+
EXAMPLE 83
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzamide
To a solution of 1.98 mL (3.966 mmol) of a 2M solution of oxalyl chloride in CH 2 Cl 2 at 0° C. was added 0.307 mL (3.966 mmol) of DMF and the mixture was stirred at 0° C. for 15 min, then let warm to room temperature and stined for an additional 1 h. A solution of 0.829 g (1.983 mmol) of the product of Example 82, in 1 mL of DMF, was then added to the reaction mixture and the reaction was stifed for 1 h at room temperature.
In a separate flask, 4.14 mL (0.030 mol) of tdethylamine was added to a 0° C. mixture of 1.378 g (0.020 mol) of hydroxylamine hydrochloride in 19.5 mL of THF and 5.6 mL of water. After this mixture had stirred for 15 min at 0° C., the acid chloride solution was added to it in one portion and the resulting solution was allowed to warm to room temperatue with stirng overnight Ie reaction mixture next was diluted with CH 2 Cl 2 and washed with water and saturated sodium bicarbonate solution. The organic layer was dried over Na 2 SO 4 , filtered and concentrated in vacuo. The crude residue was titurated with EtOAc-ether to provide 0.414 g (51%) of the tide compound as a white solid.
To a room tempeture solution of 0.403 g (0.976 mmol) of the hydroxamic acid in 10 ml of CH 2 Cl 2 --MeOH (30:1) was added 0.27 mL of a 4M HCl-ether solution. The reaction mixture was stiimd for 0.5 h and the resulting precipitate was collected by filtration and died in vacuo to provide 0.439 g (100%) of the hydrochloride salt of the title compound as a white solid. Electrospray Mass Spec: 428.2 (M+H)+.
EXAMPLE 84
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-benzoic acid
To a solution of 0.958 g (2.985 mmol) of the product of Example 1 in 7.5 mL of DMF was added 0.514 g (3.134 mmol) of 3-picolyl chloride hydrochloride and 1.30 g (9.50 mmol) of potassium carbonate. The reaction was steeed for 18 h at room temprature and then an additional 0.051 g of 3-picolyl chloride hydrochloride and 0.130 g of potassium carbonate was added and the reaction was stied for 18 h at room temperature. The reaction was then diluted with water and extracted with ether. The combined organic layers were extracted with 6N HCl solution and the aqueous acid layer was then basified with 6N NaOH solution and then extracted with ether. The resulting ether layer was dried over sodium sulfate, filtered and concentrated in vacuo. Trituration of the residue with ether provided 0.843 g (69%) of the sodium salt of the title compound as a pink solid.
To a solution of 0.830 g (2.015 mmol) of the above product in 10 mL of THF-water (1:1) was added 0.093 g of lithium hydroxide monohydrate. The reaction mixture was heated to reflux for 48 h then cooled to room temperature. The reaction mixture was then concentrated in vacuo to provide 0.813 g (100%) of the lithium salt of the tide compound as a white solid. Electrospray Mass Spec: 399.2 (M+H)+
EXAMPLE 85
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-benzamide
In the same manner as described in Example 83, 0.618 g (1.530 mmol) of the product of Example 84 provided 0.450 g (62%) of the hydrochloride salt of the title compound as a tan solid Electrospray Mass Spec: 414.2 (M+H)+
EXAMPLE 85
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3,5-dimethyl-benzoic acid methyl ester
In the same manner as described in Example 81, 1.00 g (2.865 mmol) of the product of Exalmpe 62 provided 0.932 g (74%) of the desired product as a tan solid. Electrospray Mass Spec: 441.3 (M+H)+
EXAMPLE 87
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3,5-dimethyl-benzoic acid
In the same manner as descried in Example 82, 0.810 g (1.841 mmol) of the product of Example 86 provided 0.753 g (96%) of the desired product as a tan foam. Electrospray Mass Spec: 427.3 (M+H)+
EXAMPLE 88
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3,5-dimethyl-benzamide
In the same manner as described in Example 83, 0.645 g (1.514 mmol) of the product of Example 87 provided 0.377 g (62%) of the hydrochloride salt of the title compound as a white solid. Electrospray Mass Spec: 442.3 (M+H)+
EXAMPLE 89
5-Bromo-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 81, 1.00 g (2.415 mmol) of the product of Example 10 provided 0.961 g (79%) of the desired product as a tan solid. Electrospray Mass Spec: 505.2 (M+H)+
EXAMPLE 90
5-Bromo-2- (4-metboxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid
In the same manner as described in Example 82, 0.861 g (1.708 mmol) of the product of Example 89 provided 0.837 (100%) of the lithium salt of the tide compound as a tan solid. Electrospray Mass Spec: 491.1 (M+H)+
EXAMPLE 91
5-Bromo-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzamide
In the same manner as described in Example 83, 0.767 g (1.546 mmol) of the product of Example 90 provided 0.407 g (56%) of the hydrochloride salt of the tile compound as a white solid. Electrospray Mass Spec: 506.2 (M+H)+
EXAMPLE 92
3-(4-Methoxy-benzenesulfonylamino)-naphthalene-2-carboxylic acid
In the same maaer as described in Example 4, 2.5 g (13.4 mmol) of 3-amino-2-naphthoic acid gave 2.49 g (52%) of the desired sulfonamide as a tan solid after trituation with EtOAc/hexane. Electrospray Mass Spec: 358 (M+H)+
EXAMPLE 93
3- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-naphthalene-2-carboxylic acid
In the same manner as described in Example 12, 1.2 g (3.36 mmol) of the product of Example 92 gave a brown oil which was dissolved in dioxane (20 mL) and treated with aqueous 2N sodium hydroxide. The resulting solution was heated at 80° C. for 3 days. Addition of 1N aqueous hydrochloric acid, extraction with EtOAc, drying with MgSO 4 and concentration in vacuo, followed by silica gel chromatography (hexane/EtOAc/HOAc) gave the desired carboxylic acid as a white solid (0.81 g, 54%). Electrospray Mass Spec: 448 (M+H)+
EXAMPLE 94
3- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-naphthalene-2-carboxylic acid hydroxyamide
In the same manner as described in Example 23, 200 mg (0.45 mmol) of the product of Example 94 gave 0.155 g (75%) of the desired hydroxamic acid as a white powder. Electrospray Mass Spec: 463 (M+H)+
EXAMPLE 95
3-Methoxy-2-(4-methoxy-benzenesulfonylamino)-benzoic acid
In the same mer as described in Example 4, 2.14 g (12.8 mmol) of 2-amino-3-methoxybenzoic acid gave 2.08 g (48%) of the desired sulfonamide as a beige solid after trituration with CH 2 Cl 2 :hexane (1:2). CI Mass Spec 338.0(M+H).
EXAMPLE 96
4-Chloro-2-(4-methoxy-benzenesulfonylamino)-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 1, 0.5 g (2.5 nmol) of methyl 3-methyl-4-chloro anthranilate provided 0.56 g (61%) of the desired sulfonamide as a white solid after trituration with ether. Electrospray Mass Spec 370.2(M+H).
EXAMPLE 97
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-methoxy-benzoic acid benzyl ester
In the same manner as described in Example 12, 1.73 g (5.14 mmol) of the product of Example 95 gave 2.01 g (75%) of the desired product as a white solid after silica gel chromatography eluting with CH 2 Cl 2 . CI Mass Spec 518.1 (M+H).
EXAMPLE 98
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-4-chloro-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 9, 0.5 g (1.35 mmol) of the product of Example 96 provided 0.566 g (80%) of the desired product as a white solid after trituration with hexane. Electrospray Mass Spec 460.2(M+H).
EXAMPLE 99
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-methoxy-benzoic acid
In the same manner as described in Example 19, 1.86 g (3.6 mmol) of the product of Example 97 provided 1.39 g (90%) of the desired carboxylic acid as a white solid after trituration with CH 2 Cl 2 :hexane (1:4). CI Mass Spec 428.1 (M+H).
EXAMPLE 100
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-4-chloro-3-methyl-benzoic acid
In the same manner as described in Example 19, except a mixture of MeOH and ThF was used instead of MeOH, 0.506 g (1.1 mmol) of the product of Example 98 provided 0.454 g (93%) of the desired carboxylic acid as a white solid after triion with ether. Electrospray Mass Spec 446.1(M+H).
EXAMPLE 101
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-methoxy-benzamide
In the same manner as described in Example 23, 1.25 g (2.91 mmol) of the product of Example 99 gave 1.11 g (86%) of the desired hydroxamic acid as a white solid. CI Mass Spec 443.1 (M+H).
EXAMPLE 102
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-4-chloro-N-hydroxy-3-methyl-benzamide
In the same manner as described in Example 23, 0.4 g (0.9 mmol) of the product of Example 100 provided 0.273 g (66%) of the desired hydroxamic acid as a white solid after silica gel chromatography eluting with EtOAc:hexane:acetic acid (1.0:1.5:0.5). Electrospray Mass Spec 461.2(M+H).
EXAMPLE 103
2- (4-Methoxy-benzenesulfonyl)-(3-methoxy-benzyl)-amino!-3,5-dimethyl-benzoic acid methyl ester
To a solution of 0.699 g (2.0 mmol) of the product of Example 62 in 5 mL of DMF was added 0.096 g (2.4 mmol) of 60% sodium hydride. The resulting mixture was stirred for 30 min at room temperature and then 0.376 g (2.4 mmol) of m-methoxybenzyl chloride and 0.089 g (0.24 mmol) of tetrabutylammonium iodide were added. The reaction mixure was stirred for 18 hr at room temperature, poured into water and then extracted with ether. The combined organics were washed with water and brine, dried over MgSO 4 , filtered and concentad in vacuo. The crude solid was triturated with hexane to provide 0.768 g (82%) of the desired product as white solid. Electrospray Mass Spec 470.3 (M+H).
EXAMPLE 104
2- (4-Methoxy-benzenesulfonyl)-(2,3,4,6-pentafluoro-benzyl)-amino!-3,5-dimethyl-benzoic acid methyl ester
In the same manner as described in Example 9, 0.699 g (2.0 mmol) of the product of Example 62 and 0.626 g (2.4 mmol) of pentafluorobenzyl bromide provided 1.04 g (98%) of the desired product as a white solid after trituration with hexane and preparative TLC eluting with CH 2 Cl 2 . Electrospray Mass Spec 530.1 (M+H).
EXAMPLE 105
2- (4-Methoxy-benzenesulfonyl)-propyl-amino!-3,5-dimethyl-benzoic acid methyl ester
In the same manner as described in Example 9, 0.699 g (2.0 mmol) of the product of Example 62 and 0.295 g (2.4 mmol) of 1-bromopropane provided 0.691 g (88%) of the desired product as a yellow gum after preparative TLC eluting with 1:3 EtOAc:hexane. Electrospray Mass Spec 392.2(M+H).
EXAMPLE 106
2- (2-Bromo-benzyl)-(4-methoxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid methyl ester
In the same manner as described in Example 9, 0.699 g (2.0 mmol) of the product of Example 62 and 0.6 g (2.4 mmol) of 2-bromobenzyl bromide provided 0.761 g (73%) of the desired product as a white solid after trituration with ether. Electrospray Mass Spec 518.1(M+H).
EXAMPLE 107
2- (3-Bromo-benzyl)-(4-methoxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid methyl ester
In the same manner as described in Example 9, 0.699 g (2.0 mmol) of the product of Example 62 and 0.6 g (2.4 nunol) of m-bromobenzyl bromide provided 0.954 g (92%) of the desired product as a white solid after trituration with ether. Electrospray Mass Spec 518.1 (M+H).
EXAMPLE 108
2- (4-Bromo-benzyl)-(4-methoxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid methyl ester
In the same manner as described in Example 9, 0.699 g (2.0 mmol) of the product of Example 62 and 0.6 g (2.4 mmol) of p-bromobenzyl bromide provided 0.896 g (86%) of the desired product as a white solid after trituration with hexane/ether. Electrospray Mass Spec 518.1 (M+H).
EXAMPLE 109
2- (4-Methoxy-benzenesulfonyl)-(3-methoxy-benzyl)-amino!-3,5-dimethyl-benzoic acid
To a solution of 0.610 g (1.3 mmol) of the product of Example 103 in 6.5 mL methanol and 6.5 mL of THF was added 6.5 mL of 1N NaOH solution. The reaction mixture was refluxed for 18 hr and the organics were removed in vacuo. The resulting mixture was diluted with water, acidified with 3N HCl and extracted with EtOAc. The combined organics were washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The resulting residue was triturated with ether and filtered to provide 0.417 g (79%) of the desired carboxylic acid as a white solid. Electrospray Mass Spec 456.3(M+H).
EXAMPLE 110
2- (4-Methoxy-benzenesulfonyl)-(2,3,5,6-tetrafluoro-4-methoxy-benzyl)-amino!-3,5-dimethyl-benzoic acid
In the same manner as described in Example 1109, 0.737 g (1.39 mmol) of the product of Example 104 provided 0.49 g (67%) of N-p-methoxy tetrafluroabenzyl derivative of the desired carboxylic acid after trituration with ether. Electmspray Mass Spec 528.1 (M+H).
EXAMPLE 111
2- (4-Methoxy-benzenesulfonyl)-propyl-amino!-3,5-dimethyl-benzoic acid
In the same amn as described in Example 109, 0.602 g (1.54 mmol) of the product of Example 105 provided 0.461 g (79%) of the desired carboxylic acid as a white solid after trituration with ether/hexane. Electrospray Mass Spec 378.2(M+H).
EXAMPLE 112
2- (2-Bromo-benzyl)-(4-methoxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid
In the same manner as described in Example 109, 0.518 g (1.0 mmol) of the product of Example 106 provided 0.4 g (79%) of the desired carboxylic acid as a white solid after trituration with ether. Electrospray Mass Spec 504.0 (M+H).
EXAMPLE 113
2- (3-Bromo-benzyl)-(4-methoxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid
In the same manner as described in Example 109, 0.894 g (1.725 mmol) of the product of Example 107 provided 0.61 g (70%) of the desired carboxylic acid after trituration with ether. Electrospray Mass Spec 506.0 (M+H).
EXAMPLE 114
2- (4-Bromo-benzyl)-(4-methoxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoicacid
In the same manner as described in Example 109, 0.836 g (1.61 mmol) of the product of Example 108 provided 0.584 g (72%) of the desired carboxylic acid as a white solid after trturation with ether. Electrospray Mass Spec 504 (M+H).
EXAMPLE 115
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-(3-methoxy-benzyl)-amino!-3,5-dimethyl-benzamide
In the same manner as described in Example 23, 0.364 g (0.8 mmol) of the product of Example 109 provided 0.245 g (65%) of the desired hydroxamic acid as a white solid after trituration with ether. Electrospray Mass Spec 471.3(M+H).
EXAMPLE 116
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-(2,3,5,6-tetrafluoro-4-methoxy-benzyl)-amino!-3,5-dimethyl-benzamide
In the same manner as described in Example 23, 0.369 g (0.7 mmol) of the product of Example 110 provided 0.253 g (67%) of the desired hydroxamic acid as a white solid after trituation with ether. Electrospray Mass Spec 543.1(M+H).
EXAMPLE 117
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-propyl-amino!-3,5-dimethyl-benzamide
In the same manner as described in Example 23, 0.377 g (1.0 mmol) of the product of Example 111 provided 0.294 g (75%) of the desired hydroxamic acid as a white solid after trituration with ether. Electrospray Mass Spec 393.2(M+H).
EXAMPLE 118
2- (2-Bromo-benzyl)-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3,5-dimethyl-benzamide
In the same manner as described in Example 23, 0.353 g (0.7 mmol) of the product of Example 112 provided 0.205 g (56%) of the desired hydroxamic acid as a white solid after trituration with ether. Electrospray Mass Spec 519.1 (M+H).
EXAMPLE 119
2- (3-Bromo-benzyl)-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3,5-dimethyl-benzamide
In the same manner as described in Example 23, 0.546 g (1.08 mmol) of the product of Example 113 provided 0.397 g (71%) of the desired hydroxamic acid as a white solid after trituration with ether. Electrospray Mass Spec 517.0(M-H).
EXAMPLE 120
2- (4-Bromo-benzyl)-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3,5-dimethyl-benzamide
In the same manner as described in Example 23, 0.521 g (1.03 mmol) of the product of Example 114 provided 0.333 g (62%) of the desired hydroxamic acid as a white solid after trituration with ether. Electrospray Mass Spec 517.0(M-H).
EXAMPLE 121
N-Benzyl-4-methoxy-benzenesulfonamide
To a solution of 5.358 g (0.05 mole) of benzylamine and 7.755 g (0.06 mole) of N,N-diisopropylethylamine in 80 mL of CH 2 Cl 2 at room temperatue was added slowly 11.365 g (0.055 mole) of 4-methoxybenzenesulfonyl chloride. The resulting mixture was stirred for 18 hr at room temperature and diluted with water. The organic layer was separated, washed with NaHCO 3 , water, brine, dried over MgSO 4 , filtered and concentrated. The residue was boiled in CH 2 Cl 2 :Hexane (1:4), cooled and filtered to provide 11.79 g (85%) of the desired product as a cream solid.
EXAMPLE 122
N-Benzyl-N-(2-cyano-6-trifluoromethyl-phenyl)-4-methoxy-benzenesulfonamide
To a solution of 3.05 g (11.0 mmol) of the product of Example 121 in 15 mL of DMF was added 0.484 g (12.1 mmol) of 60% sodium hydride. The resulting mixture was stirred for 30 min at room temperature and then 1.89 g (10.0 mmol) of 2-fluoro-3-(trifluoromethyl)benzonitrile in 2 mL of DMF was added. The reaction mixture was stirred at 90° C. for 18 hr, poured into water and extracted with ether. The combined organics were washed with water, brine, dried over MgSO 4 , filtered and concentrated in vacuo. The crude solid was triturated with ether to provide 3.33 g (75%) of the desired product as a white solid. Electrospray Mass Spec 447.2(M+H).
EXAMPLE 123
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-trifluoromethyl-benzamide
To a solution of 1.78 g (4.0 mmol) of the product of Example 122 in 30 mL of n-propanol was added 8 mL of 5N NaOH solution. The resulting mixture was refluxed for 66 h and concentrated. The residue was stirred in water and filtered to provide 1.725 g (93%) of the desired amide as a white solid. Electrospray Mass Spec 465.2(M+H).
EXAMPLE 124
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-trifluoromethyl-benzoic acid
To a suspension of 0.192 g (0.41 mmol) of the product of Example 123 in 2.5 mL of dry CH 3 CN was added 0.068 g(0.58 mmol) of nitrosonium tetrafluoroborate. The resulting mixture was stirred for 1 h and then added 0.040 g(0.34 mmol) of the same reagent and stirred for additional 1 h. The reaction was quenched with water and filtered to provide 0.141 g (74%) of the desired carboxylic acid as a white solid. Electrospray Mass Spec 466.2(M+H).
EXAMPLE 125
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-trifluoromethyl-benzamide
In the same manner as described in Example 23, 0.17 g (0.365 mmol) of the product of Example 124 provided 0.79 g (45%) of the desired hydroxamic acid as a cream solid. Electrospray Mass Spec 481.1 (M+H).
EXAMPLE 126
2- (4-Metboxy-benzenesulfonyl)-methyl-amino!-3,5-dimethyl-benzoic acid methyl ester
In the same manner as described in Example 9, 0.30 g (0.860 mmol) of the product of Example 62 and 0.08 mL (1.289 mmol) of iodomethaie provided 0.3 g (96%) of the desired product as a white solid. Electrospray Mass Spec 364.3(M+H).
EXAMPLE 127
2- Ethyl-(4-methoxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid methyl ester
In the same manner as described in Example 9, 0.30 g (0.860 mmol) of the product of Example 62 and 0.103 mL (1.289 mmol) of iodoethane provided 0.324 g (100%) of the desired product as a white solid. Electrospray Mass Spec 378.2(M+H).
EXAMPLE 128
2- (4-Methoxy-benzenesulfonyl)-methyl-amino!-3,5-dimethyl-benzoic acid
In the same manner as described in Example 18, 0.267 g (0.738 mrmol) of the product of Example 126 provided 0.23 g (89%) of the desired product as a white solid. Electrospray Mass Spec 350.1(M+H).
EXAMPLE 129
2- Ethyl-(4-methoxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid
In the same manner as described in Example 18, 0.254 g (0.674 mmol) of the product of Example 127 provided 0.207 g (84%) of the desired product as a white solid. Electrospray Mass Spec 364.2(M+H).
EXAMPLE 130
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3,5-dimethyl-benzamide
In the same manner as described in Example 23, 0.194 g (0.557 mmol) of the product of Example 128 provided 0.140 g (69%) of the desired product as a white solid. Electrospray Mass Spec 365.3(M+H).
EXAMPLE 131
2- Ethyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3,5-dimethyl-benzamide
In the same manner as described in Example 23, 0.175 g (0.482 mmol) of the product of Example 129 provided 0.142 g (78%) of the desired product as a white solid. Electrospray Mass Spec 379.2(M+H).
EXAMPLE 132
2-Amino-5-bromo-3-methyl-benzoic acid
To a mixture of 1.5 g (10 mmol) of 3-methyl-2-amino benzoic acid in 50 mL of glacial acetic acid was added 1.6 g (10 mmol) of Iromine and the resulting mixture was stirred at room temperature for 5 h. The reaction mixture was then poured into water and the precipitated solid was filtered, washed with water and air dried to provide 2.2 g (95%) of the desired product as a brown solid. m.p.245° C. Electrospray Mass Spec 232 (M+H).
EXAMPLE 133
2-Amino-5-bromo-3-methyl-benzoic acid methyl ester
To 20 mL of 50% BF 3 :MeOH complex was added 2.3 g (10 mmol) of the product of Example 132 and the mixture was heated to reflux for 48 h. The reaction mixture was then cooled to room temperature, concentrated in vacuo, diluted with ice water and neutralized with 1N NaOH solution. The resulting mixture was extracted with chloroform, and the combined organics were washed with water, dried over MgSO 4 , filtered and concentrated in vacuo to provide 2.3 g (93%) of the desired product as a brown semi-solid. Electrospray Mass Spec 246 (M+H).
Example 134
5-Bromo-2-(4-methoxy-benzenesulfonylamino)-3-methyl-benzoic acid methyl ester
To a stirred solution of 24.5 g (100 mmol) of the product of Example 133 in 100 mL of pyrdine was added 21.0 g (100 mmol) of p-methoxybenzenesulfonyl chloride and the resulting mixture was heated to 80° C. for 24 h. The reaction mixture was then quenched with ice cold water and acidified with concentrated HCl. The resulting mixture was extracted with chloroform, washed with water, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was triteretd with diethyl ether, filtered and dried to provide 35 g (84%) of the desired product as a brown solid. Electrospray Mass Spec 416, (M+H).
EXAMPLE 135
3-Bromo-2-(4-methoxy-benzenesulfonylamino)-5-methyl-benzoic acid methyl ester
To a solution of 2.4 g (10 mmol) of methyl 2-amino-3-bromo-5-methyl benzoate in 20 mL of pyridine was added 2.1 g (10 mmol) of p-methoxybenzenesulfonyl chloride. The reaction mixture was then heated to 70° C. for 16 h and then poured into ice water and acidified with concentrated hydrochloric acid to pH2. The resulting mixture was extracted with chloroform, washed with water, dried over anhydrous MgSO 4 , filtered and conntrated in vacuo. The residue was triturated with ether, filtered and dried to provide 3.8 g (92%) of the desired product as a brown solid. m.p. 113° C. Electrospray Mass Spec: 416 (M+H).
EXAMPLE 136
3-Bromo-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-benzoic acid methyl ester
To a sired solution of 2.0 g (4.8 nmnol) of the product of Example 135 in 20 mL of DMF was added 1.0 g (10 mmol) of K 2 CO 3 and 1.1 g (7.2 mmol) of 3-picolyl chloride hydrochloride. The reaction niixture was stirred for 48 h at room tempera and then diluted with water. The resulting mixture was extracted with chloroform and the combined organic layers were washed with water, dried over MgSO 4 , filtered and concentraed in vacuo. The residue was purified by chromatography on silica gel eluting with ethyl acetate. hexane (1:1) to provide 2.90 g (82%) of the desired product as a brown oil. Electrospray Mass Spec: 508 (M+H).
EXAMPLE 137
3-Bromo-2- (4-methoxy-benzenesulfonyl-pyridin-3-ylmethyl)-amino!-5-methyl-benzoic acid
In the same manner as described in Example 16, 1.01 g (2 mmol) of the product of Example 136 provided 0.90 g (91%) of the desired product as a white powder after neutraliation of the reaction mixture with acetic acid and extraction with ethyl acetate. m.p.198° C. Electrospray Mass Spec: 494 (M+H).
EXAMPLE 138
3-Bromo-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-benzamide
In the same manner as described in Example 23, 0.986 g (2 mmol) of the product of Example 137 provided 0.61 g (60%) of the title product. The corresponding hydrochloride salt was prepared in quantitative yield by bubbling HCl gas through a methanolic solution of the free base, followed by concentrating the reaction mixture in vacuo to provide a yellow spongy solid. m.p.87° C. Electrospray Mass Spec: 509 (M+H).
EXAMPLE 139
2-(4-Methoxy-benzenesulfonylamino)-3-methyl-5-thiophen-2-yl-benzoic acid methyl ester
To a solution of 3.0 g (7.2 mmol) of the product of Example 134 in 200 mL of degassed toluene was added 3.54 g (10 mmol) of 2-thienyl tdbutyltin and 0.50 g of tetmis(triphenylphosphine)palladium and the resulting mixture was refluxed for 16 h. The reaction mixture was then filtered through celite and the filtrate was concentrated in vacuo. The residue was chromatographed on silica gel eluting with 30% ethylacetate:hexane to provide 2.5 g (83%) of the desired product as a gray solid. m.p.91° C. Electrospray Mass Spec: 417 (M+H).
EXAMPLE 140
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5-thiophen-2-yl-benzoic acid methyl ester
In the same manner as described in Example 136, 0.832 g (2.0 mmol) of the product of Example 139 provided 0.920 g of the desired product as a brown oil. Electrospray Mass Spec: 509 (M+H).
EXAMPLE 141
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5-thiophen-2-yl-benzoic acid
In the same manner as described in Example 18, 0.800 g (1.5 mmol) of the product of Example 140 provided 0.70 g (94%) of the desired product as a white solid. m.p.191° C. Electrospray Mass. Spec: 495 (M+H).
EXAMPLE 142
2-(4-Methoxy-benzenesulfonylamino)-5-methyl-3-thiophen-2-yl-benzoic acid methyl ester
In the same manner as described in Example 39, 3.0 g (7.2 mmol) of the product of Example 135 provided 2.0 g (66%) of the desired product as a gray solid after chromatography on silica gel eluting with 30% ethyl acetate:hexane. m.p.141° C. Electrospray Mass Spec: 418 (M+H).
EXAMPLE 143
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-3-thiophen-2-yl-benzoic acid methyl ester
In the same manner as described in Example 136, 2.0 g (4.8 mmol) of the product of Example 142 provided 2.1 g (87%) of the desired product as a brown oil after chromatography on silica gel eluting with 50% ethyl acetate:hexane. Electrospray Mass Spec: 509 (M+H).
Example 144
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-3-thiophen-2-yl-benzoic acid
In the same manner as described in Example 16 starting with 1.5 g (2.9 mmol) of the product of Example 143 provided 1.3 g (86%) of the desired product as a white powder after neutralization of the reaction mixture with acetic acid and extraction with ethyl acetate. m.p.67° C. Electrospray Mass Spec: 495 (M+H).
EXAMPLE 145
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-3-thiophen-2-yl-benzamide
In the same manner as described in Example 23, 1.0 gm (2.02 mmol) of the product of Example 144 provided 0.70 g (63%) of the desired product. The corresponding hydrochloride salt was prepared in quantitative yield by bubbling HCl gas through a methanolic solution of the free base, followed by concentrating the reaction mixture in vacuo to provide a yellow spongy solid. m.p.94° C. Electrospray Mass Spec: 547 (M+H).
EXAMPLE 146
2- (4-Methoxy-benzenesulfonyl)-methyl-amino!-3,5-dimethyl-benzoic acid methyl ester
In the same manner as described in Example 9, 0.30 g (0.860 mmol) of the product of Example 62 was alkylated with methyl iodide to give 0.30 g (96%) of the desired product as a white solid. Electrospray Mass Spec: 364 (M+H).
EXAMPLE 147
2- Ethyl-(4-methoxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid methyl ester
In the same manner as described in Example 9, 0.30 g (0.860 mmol) of the product of Example 62 was alkylated with ethyl iodide to give 0.324 g (100%) of the desired product as a white solid. Electrospray Mass Spec: 378 (M+H).
EXAMPLE 148
2- (4-Methoxy-benzenesulfonyl)-methyl-amino!-3,5-dimethyl-benzoic acid
In the same manner as described in Example 18, 0.267 g (0.738 mmol) of the product of Example 146 gave 0.23 g (89%) of the desired product as a white solid. Electrospray Mass Spec: 350 (M+H).
EXAMPLE 149
2- Ethyl-(4-methoxy-benzenesulfonyl)-amino!-3,5-dimethyl-benzoic acid
In the same manner as described in Example 18, 0.254 g (0.674 mmol) of the product of Example 147 gave 0.207 g (84%) of the desired product as a white solid. Electrospray Mass Spec: 364 (M+H).
EXAMPLE 150
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3,5-dimethyl-benzamide
In the same manner as described in Example 23, 0.194 g (0.557 mmol) of the product of Example 148 gave 0.140 g (69%) of the desired product as a pink solid. Electrospray Mass Spec: 365 (M+H).
EXAMPLE 151
2- Ethyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3,5-dimethyl-benzamide
In the same manner as described in Example 23, 0.175 g (0.482mnol) of the product of Example 149 gave 0.142 g (78%) of the desired product as a white solid. Elec pray Mass Spec: 379 (M+H).
EXAMPLE 152
3,4,5-Trimethoxy-2-(4-methoxy-benzenesulfonylamino)-benzoic acid methyl ester
In the same manner as described in Example 31, 2.0 g (8.289 mmol) of methyl-3,4,5-trimethylanthranilate gave 1.945 (57%) of the desired product as a white solid. Electrospray Mass Spec: 412 (M+H).
EXAMPLE 153
3,4,5-Trimethoxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-benzoic acid methyl ester
In the same manner as described in Example 45, 0.60 g (1.46 mmol) of the product of Example 152 gave 0.716 g (98%) of the desired product as a brown oil. Electrospray Mass Spec: 503 (M+H).
EXAMPLE 154
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3,4,5-trimethoxy-benzoic acid methyl ester
In the same manner as described in Exampk 9, 0.60 g (1.46 mmol) of the product of Example 152 gave 0.669 g (92%) of the desired product as a white solid. Electrospray Mass Spec: 502 (M+H).
EXAMPLE 155
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3,4,5-trimethoxy-benzoic acid
In the same manner as described in Example 18, 0.594 g (1.186 mmol) of the product of Example 154 gave 0.532 g (92%) of the desired product as a white solid. Electay Mass Spec: 488 (M+H).
EXAMPLE 156
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3,4,5trimethoxy-benzamide
In the same manner as described in Example 23, 0.463 g (0.951 mmol) of the product of Example 155 gave 0.353 g (74%) of the desired product as a white solid. Electrospray Mass Spec: 503 (M+H).
EXAMPLE 157
3,4,5-Trimethoxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-benzoic acid
In the same manner as described in Example 53, 0.640 g (1.275 mrol) of the product of Example 153 gave 0.631 g (100%) of the desired product as a tan foam. Eiectrospray Mass Spec: 489 (M+H).
EXAMPLE 158
N-Hydroxy-3,4,5-trimethoxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-benzamide
In the same manner as described in Example 61, 0.549 g (1.109 mmol) of the product of Example 157 gave 0.395 g (71%) of the desired product as a brown foam. Electrospray Mass Spec: 504 (M+H).
EXAMPLE 159
12-(4-Methoxy-benzenesulfonyl)-11,12-dihydro-6H-dibenz b,f! 1,4!oxazocine-1-carboxylic acid methyl ester
To a solution of 0.350 g (1.039 mmol) of the product of Example 31 in 35 mL of DMF was added 0.104 g (2.596 mmol) of 60% sodium hydride and the solution was stirred at room temperature for 15 minutes. To the resulting mixture was then added 0.384 g (1.454 mmol) of a,a'-dibromo-o-xylene and the reaction mixture was then heated to 80° C. for 18 h, cooled to room temperature, diluted with ether and washed with water. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo. The resulting residue was chromatographed on silica gel eluting with EtOAc/hexanes (1:3) to provide 0.358 g (79%) of the desired product as a white solid. Electrospray Mass Spec: 440 (M+H).
EXAMPLE 160
6-(4-Methoxy-benzenesulfonyl)-3,4,5,6-tetrahydro-2H -1,6-benzoxazocine-7-carboxylic acid methyl ester
In the same manner as described in Example 159, 0.400 g (1.187 mmol) of the product of Example 31 and 0.198 mL (1.662 mmol) of 1,4-dibromobutane provided 0.139 g (30%) of the desired product as a white solid. Electrospray Mass Spec: 392 (M+H).
EXAMPLE 161
5-(4-Methoxy-benzenesulfonyl)-2,3,4,5-tetrahydro- 1,5!benzoxazepine-6-carboxylic acid methyl ester
In the same manner as described in Example 159, 0.300 g (0.890 mmol) of the product of Example 31 and 0.127 mL (1.246 mmol) of 1,3-dibromopropane provided 0.156 g (46%) of the desired product as a colorless oil. Electrospray Mass Spec: 378 (M+H).
EXAMPLE 162
5-(4-Methoxy-benzenesulfonyl)-2,3,4,5-tetrahydro-1,5-benzoxazepine-6-carboxylic acid
In the same manner as described in Example 18, 0.174 g (0.462 mmol) of the product of Example 161 provided 0.133 g (79%) of the desired product as a white solid. Electrospray Mass Spec: 364 (M+H).
EXAMPLE 163
12-(4-Methoxy-benzenesulfonyl)-11,12-dihydro-6H-dibenz b,f! 1,4!oxazocine-1-carboxylic acid
In the same manner as described in Example 18, 0.306 g (0.697 mmol) of the product of Example 159 provided 0.261 g (88%) of tie desired product as a white solid. Electrospray Mass Spec: 426 (M+H).
EXAMPLE 164
6-(4-Methoxy-benzenesulfonyl)-3,4,5,6-tetrahydro-2H-1,6-benzoxazocine-7-carboxylic acid
In the same manner as described in Example 18, 0.125 g (0.320 mmol) of the product of Example 160 provided 0.106 g (88%) of the desired product as a white solid Electrospray Mass Spec: 378 (M+H).
EXAMPLE 165
5-(4-Methoxy-benzenesulfonyl)-2,3,4,5-tetrahydro-1,5-benzoxazepine-6-carboxylic acid hydroxyamide
In the same manner as described in Example 23, 0.107 g (0.295 mmol) of the product of Example 162 provided 0.100 g (90%) of the desired product as a white solid. Electrospray Mass Spec: 379 (M+H).
EXAMPLE 166
12-(4-Methoxy-benzenesulfonyl)-11,12-dihydro-6H-dibenz b,f! 1,4!oxazocine-1-carboxylic acid hydroxyamide
In the same manner as described in Example 23, 0.230 g (0.541 mmol) of the product of Example 163 provided 0.192 g (81%) of the desired product as a white solid. Elecray Mass Spec: 441 (M+H).
EXAMPLE 167
6-(4-Methoxy-benzenesulfonyl)-3,4,5,6-tetrahydro-2H-1,6-benzoxazocine-7-carboxylic acid hydroxyamide
In the same manner as described in Example 23, 0.081 g (0.215 nmnol) of the product of Example 164 provided 0.074 g (88%) of the desired product as a white solid. Electrospray Mass Spec: 393 (M+H).
EXAMPLE 168
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-nitro-benzoic acid methyl ester
To a solution of 29.5 g (0.092mol) of the product of Example 1 suspended in 131 mL of acetic anhydride at 0° C. was dropwise added a mixture of 17.5 mL of acetic anhydride, 22.5 mL of 70% nitric acid and 15.75 mL of acetic acid over 1 hour. The reaction was stirred at 0° C. for an additional 2 h and then poured into ice water. The precipitate was filtered and washed with ether. The filtrate was transferred to a separatory funnel and the layers were separated. The aqueous layer was washed with chloroform and the combined organics were dried over MgSO 4 , filtered and concentred in vacuo. The residue was chromatographed on silica gel eluting with EtOAc/Hexanes (1:10) to provide 1.03 g of the nitro-sulfonamide as a yellow solid.
0.250 g (0.683 mmol) of the sulfonamide reacted with sodium hydride and benzyl bromide in the same manner as described in Example 9 to provide 0.215 g (69%) of the desired product as a pale yellow solid. Electrospray Mass Spec: 457 (M+H).
EXAMPLE 169
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-nitro-benzoic acid
In the same manner as described in Example 18, 0.199 g (0.436 mmol) of the product of Example 168 provided 0.172 g (89%) of the desired product as a pale yellow solid. Electrospray Mass Spec: 443 (M+H).
EXAMPLE 170
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-nitro-benzamide
In the same manner as described in Example 23, 0.136 g (0.308 mmol) of the product of Example 169 provided 0.106 g (75%) of the desired product as a tan foam. Electropray Mass Spec: 458 (M+H).
EXAMPLE 171
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3- 3-(tert-butyl-dimethyl-silanyloxy)-propoxy!-benzoic acid methyl ester
In the same manner as described in Example 38, 0.35 g (0.820 mmol) of the product of Example 37 and 0.290 g (1.147 mmol) of 1-t-butyldimethylsilyloxy-3-bromopropane provided 0.355 g (72%) of the desired product as a colorless oil. Electrospray Mass Spec: 600 (M+H).
EXAMPLE 172
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-(3-hydroxy-propoxy)-benzoic acid
In the same manner as described in Example 18, 0.310 g (0.518 mmol) of the product of Example 171 provided 0.188 g (77%) of the desired product as a white foam. Electrpray Mass Spec: 470 (M-H).
EXAMPLE 173
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3- 3-(tert-butyl-dimethyl-silanyloxy)-propoxy!-benzoic acid
To a solution of 0.145 g (0.308 mmol) of the product of Example 172 in 5.0 mL of DMF was added 0.105 g (1.539 mmol) of iidazle and 0.111 g (0.739 mmol) of t-butyidimethylsilyl chloride. The reaction was stirred at room temperature for 18 h and then 0.40 mL of 1N sodium hydroxide solution was added and the resulting mixture was sired for 1 h. The reaction mixture was then diluted with water, acidified with 5% HCl solution and extted with EtOAc. The combined organics were washed with water, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel eluting with EtOAc/Hexanes to provide 0.089 g (50%) of the desired product as a white foam. Electrospray Mass Spec: 586 (M+H).
EXAMPLE 174
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy 3-(3-hydroxy-propoxy)-benzamide
In the same manner as described in Example 23, 0.073 g (0.125 mmol) of the product of Example 173 provided 0.038 g (62%) of the desired product as a white solid. Electrospray Mass Spec: 487 (M+H).
EXAMPLE 175
N-Hydroxy-2- (4-methoxybenzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5-thiophen-2-yl benzamide
In the same manner as described in Example 23, 0.600 g (1.2 mmol) of the product of Example 141 provided 0.520 g (79%) of the desired product after chromatography on silica gel eluting with 5% MeOH:Ethyl acetate. The corresponding hydrochloride salt was prepared in quantitative yield by bubbling HCl gas through a methanolic solution of the free base, followed by concentrating the reaction mixture in vacuo to provide a yellow spongy solid. m.p.106° C. Electrospray Mass Spec: 547 (M+H).
EXAMPLE 176
3-Cyano-2-(4-methoxybenzenesulfonylamino)-5-methylbenzoic acid
To a solution of 4.0 g (10 mmol) of the product of Example 135 in 60 ml of pyridine was added 2.0 g (22 mmol) of copper (I) cyanide and the mixture was refluxed for 48 h. The reaction mixture was then cooled to room tempera and poured over cold water. The resulting mixture was stirred for sixteen hours and carefully acidified with concentted HCl solution. The resulting precipitate was filtered and washed with water, dissolved in chloroform, filtered and concentrated. The residue was triturated with ether, filtered and dried to provide 2.5 g (72%) of the desired product as a white solid. m.p. 162° C.; Electrospray Mass Spec 347 (M+H).
EXAMPLE 177
2- Benzyl-(4-methoxybenzenesulfonylamino)-3-cyano-5-methylbenzoic acid
To a solution of 1.5 g (4.3 mmol) of the product of Example 176 in 200 mL of acetone was added 4 g of K 2 CO 3 and 5 ml of benzylbromide and the mixture was refluxed for 8 hours. The reaction mixture was then filtered and the acetone was removed in vacuo. The residue was dissolved in chloroform and washed well with water. The organic layer was then dried over MgSO 4 , filtered and concentrated in vacuo. The resulting residue chromatographed on silica gel luting with 30% Ethyl acetateexane to give 1.8 g (79%) of the desired product as a brown oil. Electrospray Mass Spec 527 (M+H).
EXAMPLE 178
2- Benzyl-(4-methoxybenzenesulfonylamino)-3-cyano-5-methyl-benzoic acid
To a solution of 1.5 g (2.8 mmol) of the product of Example 177 in 100 mL of ThF:MeOH (1:1) was added 10 mL of 10N NaOH. The reaction mixture was stired at room temperature for 8 h and then concentrated in vacuo. The residue was neutlized with concentrated HCl and the resulting separated solid was dissolved in chloroform and washed well with water. The organic layer was dried over MgSO 4 , filtered and concentrated. The resulting solid was triturated with ether and filtered to provide 1.1 g (91%) of the desired product as a brown solid. Electrospray Mass Spec 437 (M+H).
EXAMPLE 179
2- Benzyl-(4-methoxybenzenesulfonylamino)-N-hydroxy-3-cyano-5-methyl-benzamide
In the same manner as described in Example 23, 1.0 g (2.3 mmol) of the product of Example 178 provided 0.70 g (67%) of the desired product as a white solid. m.p. 175° C.; Electrospray Mass Spec 452 (M+H).
EXAMPLE 180
5-Cyano-2-(4-methoxybenzenesulfonylamino)-3-methyl-benzoic acid
To a solution of 4.0 g (10 mmol) of the product of Example 10 in 60 mL of pyridi was added 2.0 g (22 mmol) of copper (I) cyanide and the resulting mixture was refluxed for 48 h. The reaction mixture was then cooled to room temperature, poured over cold water, stirred for 16 h and then carefully acidified with concentrated HCl solution. The resulting solid was filtered and washed with water, dissolved in chloroform, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was triturated with ether, filtered and dried to provide 2.0 g (58%) of the desired product as a white solid. m.p. 175° C.; Electrospray Mass Spec 347 (M+H).
EXAMPLE 181
2- Benzyl-(4-methoxybenzenesulfonylamino)-5-cyano-3-methylbenzoic acid
In the same manner as described in Example 177, 4.5 g (13 mmol) of the product of Example 180 and 5 mL of benzylbromide provided 3.5 g (51%) of the desired product as brown solid after trituration with ether. m.p. 123° C.; Electrospray Mass Spec 527 (M+H).
EXAMPLE 182
2- Benzyl-(4-methoxybenzenesulfonylamino)-5-cyano-3-methyl-benzoic acid
In the same manner as described in Example 178, 3.0 g (5.7 mmol) of the product of Example 215 provided 2.2 g (88%) of the desired product as a brown semi-solid. Electrospray Mass Spec 437 (M+H).
EXAMPLE 183
3-Furan-2-yl-2-(4-methoxybenesulfonylamino)-5-methyl-benzoic acid methyl ester
To a solution 4.1 g (10 mmol) of the product of Example 135 in 300 mL of degassed toluene was added 6.0 g (16 mmol) of 2-(tributylstannyl)furan and 500 mg of tetrakis(triphenylphosphine)palladium(0) and the resulting mixture was heated to reflux for 24 h. The reaction mixture was then cooled, filtered through celite and concentrated in vacuo. The resulting residue was triturated with either to provide 3.5 g (87%) of the desired product as a grey solid. m.p. 133° C.; Electrospray Mass Spec 402 (M+H).
EXAMPLE 184
3-Furan-2-yl-2- (4-methoxybenzenesulfonyl)-pyridin-3-ylmethylamino!-5-methyl-benzoic acid methyl ester
To a solution of 3.0 g (7.4 mmol) of the product of Example 183 in 25 mL of DMF was added 1.64 g (10 mmol) of 3-picolyl chloride hydrochloride and 4.0 g of K 2 CO 3 and the resulting mixture was stirred for 72 h at room temperature. The reaction mixture was then poured over water, extracted with chloroform and washed well with water. The organic layer was dried over anhydrous MgSO 4 , filtered and concentratedin vacuo. The residue was chromatographed on silica gel eluting with 50% ethyl acetate/hexane to provide 2.5 g (68%) of the desired product as a brown oil. Electrospray Mass Spec 493 (M+H).
EXAMPLE 185
3-Furan-2-yl-2- (4-methoxybenzenesulfonyl)-pyridin-3-ylmethylamino!-5-methyl-benzoic acid
In the same manner as descibed in Example 24 2.0 g (4.0 mmol) of the product of Example 184 provided 1.5 g (79%) of the desired product as a brown solid. m.p. 82° C.; Electrospray Mass Spec 479 (M+H).
EXAMPLE 186
3-Furan-2-yl-N-hydroxy-2- (4-methoxybenzenesulfonyl)-pyridin-3-ylmethylamino!-5-methyl-benzamide
In the same manner as described in Example 23, 1.0 g (2.01 mmol) of the product of Example 185 provided 0.60 g (58%) of the desired product as a white solid after chroatography on silica gel eluting with ethyl acetate/methanol (95:5) m.p. 160° C.; Electrosray Mass Spec 494 (M+H).
EXAMPLE 187
2- (4-Methoxybenzenesulfonyl)-methylamino!-3-methyl-benzoic acid methyl ester
To a solution of 1.0 g (2.985 mmol) of the product of Example 3 in 10 mL of DMF was added 0.149 g (3.731 mmol) of 60% sodium hydride. The resulting mixture was stirred for 30 minutes at room temperature and then 0.28 mL (4.478 mmol) of iodomethane was added. The reaction was then stirred for 18 h, and next diluted with ether. The organics were washed with water, dried over MgSO 4 , filtered and concentrated in vacuo to provide a white solid. The solid was washed with ether/hexanes (1:1) to give 0.788 g (76%) of the desired product as a white solid. Electrospray Mass Spec: 350.1 (M+H).
EXAMPLE 188
3-Bromomethyl-2- (4-methoxybenzenesulfonyl)-methylamino!-benzoic acid methyl ester
To a solution of 0.723 g (2.072 mmol) of the product of Example 187 in 70 mL of carbon tetrachloride was added 0.406 g (2.279 mmol) of N-bromosuccinimide and 0.14 g of dibenzoyl peroxide. The resulting mixture was heated to reflux for 18 h and then cooled to room temperature, washed with sodium bisulfite solution and water, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was titurad with ether/hexanes (1:1) and then filtered to provide 0.504 g (57%) of the desired product as a white solid. Electrspray Mass Spec: 428 (M+H).
EXAMPLE 189
3-Diethylaminomethyl-2- (4-methoxybenzenesulfonyl)-methylamino!benzoic acid methyl ester
To a solution of 0.25 g (0.584 nmol) of the product of Exmple 188 in 2.0 mL of DMF was added 0.242 g (1.752 mrol) of potassium carbonate, 0.066 mL (0.643 mmol) of diethylamine and 2 mg of tetrabutylanmonium iodide. The reaction mixture was then stirred at room temperature for 5 h, diluted with water and extracted with ether. The organics were then extracted with 6N HCl solution and the aqueous acid layer was then basified with 6N NaOH solution and then extracted with ether. The resulting ether layer was died over sodium sulfate, filtered and concentrated in vacuo to provide 0.19 g (78%) of the desired product as a colorless oil. Electrospray Mass Spec: 421.3 (M+H) +
EXAMPLE 190
3-Diethylaminomethyl-2- (4-methoxybenzenesulfonyl)-methylamino!benzoic acid
To a solution of 0.158 g (0.376 mmol) of the product of Example 189 in 4.0 mL of THF/water/MeOH (1:1:0.5) was added 0.032 g (0.752 mmol) of lithium hydroxide amonohydrate and the resulting mixture was then heated to reflux for 18 h, cooled to room temperature and concentrated in vacuo. The residue was washed with THF and filtered, and the filtrate was then concentrated and dried in vacuo to provide 0.132 g (85%) of the lithium salt of the tide compound as a white foam. Electrospray Mass Spec: 407.2 (M+H) +
EXAMPLE 191
3-Diethylaminomethyl-N-hydroxy-2- (4-methoxybenzenesulfonyl)-methylamino!benzamide
In the same manner as described in Example 61, 0.110 g (0.267 mmol) of the product of Example 190 provided 0.125 g (100%) of the hydrochloride salt of the tide comod as a brown foam. Electrospray Mass Spec: 422.1 (M+H)+.
EXAMPLE 192
2- (4-methoxybenzenesulfonyl)-methylamino!-3-(4-methylpiperazin-1-ylmethyl)-benzoic acid methyl ester
In the same manner as described in Example 189, 0.500 g (1.168 mmol) of the product of Example 188 and 0.143 mL (1.285 mmol) of N-methylpiperazine provided 0.368 g (70%) of the desired product as a tan solid. Electrospray Mass Spec: 448.0 (M+H) +
EXAMPLE 193
2- (4-methoxybenzenesulfonyl)-methylamino!-3-(4-methylpiperazin-1-ylmethyl)-benzoic acid
In the same manner as described in Example 190, 0.310 g (0.693 mmol) of the product of Example 192 provided 0.305 g (100%) of the lithium salt of the tide compound as a white foam Electrospray Mass Spec: 432.1 (M-H) -
EXAMPLE 194
N-Hydroxy-2- (4-methoxybenzenesulfonyl)-methylamino!-3-(4-methylpiperazin-1-ylmethyl)-benzamide
In the same manner as described in Example 61, 0.150 g (0.334 mmol) of the product of Example 193 provided 0.174 g (100%) of the hydrochloride salt of the title compound as a brown solid. Electrospray Mass Spec: 448.9 (M+H) +
EXAMPLE 195
2- Benzyl-(4-methoxybenzenesulfonyl)amino!-3-(1-ethoxycarbonyl-1-methylethoxy-benzoic acid methyl ester
To a solution of 0.250 g (0.585 mm01) of the product of Example 37, in 10 mL of DMF was added 2.42 g (17.56 mmol) of potassium carbonate and 0.86 mL (5.854 mmol) of ethyl 2-bromoisobutyrate. The resulting mixture was heated to 80° C. for 18 h and then cooled to room temperature and diluted with ether. The organics were washed with water, dried over MgSO 4 , filtered and concentrated in vacuo to provide 0.186 g (59%) of the desired product as a white solid. Electrospray Mass Spec: 442.2 (M+H) + .
EXAMPLE 196
2- Benzyl-(4-methoxybenzenesulfonyl)amino!-3-(1-ethoxycarbonyl-1-methylethoxy-benzoic acid
In the same manner as described in Example 9, 0.147 g (0.272 mmol) of the product of Example 195 provided 0.107 g (79%) of the desired product as a white solid. Electrospray Mass Spec: 500.2 (M+H) +
EXAMPLE 197
2- Benzyl-(4-methoxybenzenesulfonyl)amino!-3-(1-ethoxycarbonyl-N-hydroxy-1-methylethoxy-benzamide
In the same manner as described for Example 23, 0.085 g (0.170 mmol) of the product of Example 196 provided 0.052 g (58%) of the desired product as a white solid. Electrospray Mass Spec: 530.1 (M+H) +
EXAMPLE 198
3-Bromo-2 -(4-methoxybenzenesulfonyl)amino!-benzoic acid methyl ester
To 0.096 g (0.5 mmol) of 4-methoxyphenylsulphonamide in 3 mL of DMF was added in one portion 0.020 g (0.50 mmol) of 60% sodium hydride and the reaction was stirre at 25° C. for 15 min. Then, 0.135 g (0.58 mmol) of methyl 3-bromo-2-fluorobenzylate was added to the solution in one portion and the resulting mixture was heated at 90° C. (bath temperature) for 18 h. The reaction was cooled to room temperature, acidified with 1N HCl and extracted with ethyl acetate. The combined organic layers were dried over magnesium sulfate, filtered and concentrated in vacuo. The residue was chromatographed on silica eluting with 30%-50% ethyl acetate/hexane to provide 0.037 g (19%) of the desired product. 1 HNMR(CDCl 3 ): 8 ppm (s, 1H, NH), 6.8-7.8 ppm (m, 7H, Ar), 3.9 ppm (s, 1H, OMe), 3.7 ppm (s, 1H, OMe).
EXAMPLE 199
3-Bromo-2- benzyl-(4-methoxybenzenesulfonyl)amino!-benzoic acid methyl ester
To a solution of 0.413 g (1.03 mmol) of the product of Example 198 in 10 mL of DMF was added 0.062 g (1.55 mmol) of 60% sodium hydride. Stirring was continued for 15 min at 25° C. and 0.125 mL (1.442 mmol) of benzyl bromide was then added and the mixture was stird for 18 h at 55° C. The reaction was cooled to room temperature and the reaction mixture was poured into 200 mL water and 50 mL 1N HCl. The aqueous layer was then extracted with dichlromethane (100 mL) and ethyl acetate (100 mL). The combined organic layers were dried over magnesium sulfate, filtered and concentrated in vacuo. The residue was chromatographed on silica eluting with 10%-20% ethyl acetate/hexane to provide 0.390 g (77%) of the desired product. Electrospray Mass Spec 490.0 (M+H)
EXAMPLE 200
3-Bromo-2- benzyl-(4-methoxybenzenesulfonyl)amino!-benzoic acid
In the same manner as described in Example 16, 0.390 g (0.80 mmol) of the product of Example 199 provided 0.180 g (84%) of the desired carboxylic acid as a white solid. 1 HNMR(CDCl 3 ): 9-10 ppm (br, 1H, COOH), 7-8 ppm (m, 12H, Ar), 4.5 ppm (m, 2H, --CH 2 --), 3.9 ppm (s, 1H, OMe).
EXAMPLE 201
3-Bromo-2- benzyl-(4-methoxybenzenesulfonyl)amino!-N-hydroxy-benzamide
In the same manner as described in Example 23, 0.177 g (0.372 mmol) of the product of Example 200 gave 0.155 g (85%) of the desired hydroxamic acid as a white solid. Electrospray Mass Spec: 491.0 (M+H).
EXAMPLE 202
5-Bromo-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 9, 27.0 g (65 mmol) of the product of Example 10 and 4.87 ml (78 mmol) of methyl iodide provided 22.06 g (86%) of the desired product as a white solid after trituration with ether. Electrospray Mass Spec 430 (M+H).
EXAMPLE 203
5-(2-tert-Butoxycarbonyl-vinyl)-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid methyl ester
A mixture of 1.28 g (3.0 mmol) of the product of Example 202, 1.31 ml (9.0 mmol) of t-butylacrylate, 33.75 mg (0.15 mmol) of palladium diacetate, 1.0 g (3.15 mmol) of t-butyl ammonium bromide and 1.24 g (9.0 mmol) of K 2 CO 3 in 10 ml of DMF was stifled at 85° C. for 6 h. The reaction mixture was poured into water and extracted with ethyl acetate. The combined organics were washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The resulting residue was dissolved in 20 ml of dichloromethane and stired with 1.0 g of celite and 1.0 g of silica gel for 20 min, filtered and concentnted in vacuo. The resulting residue was chromatographed on silica gel eluting with ETOAc/Hexane (1:5) to provide 1.26 g (88%) of the desired product as a white solid. Electrospray Mass Spec 476(M+H).
EXAMPLE 204
5-(2-Carboxy-vinyl)-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid methyl ester
To a solution of 237.8 mg (0.5 mmol) of the product of Example 203 in 2 ml dichlocomethane, was added lml of trifluoroacetic acid and the reaction was stirre at room temperature for 2 h. The resulting mixture was concentrated in vacuo to provide 200 mg (95%) of the desired product as a white solid after trituration with hexane/ether (2:1). Electrospray Mass Spec 418(M-H).
EXAMPLE 205
2- (4-Methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-5- 2-(methyl-octyl-carbamoyl)-vinyl!-benzoic acid methyl ester
A mixture of 182.6 mg (0.43 mmol) of the product of Example 204, 183 mg of molecular sieves and 105.8 mg (0.65 mmol) of 1,1'-dicyclohexylcarbodiimidazole in 4 ml THF was stirred for 1 h under nitrogen. A solution of N-methyloctylamine in 0.5 ml THF was then added to the reaction and the mixture was stirred for 18 hr at room temperature. The resulting mixture was filtered and the filtrate was diluted with ethyl acetate, washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel eluting with EtOAc/Hexane (1:1) to provide 200 mg (84%) of the desired product as a colorless oil. Electrospray Mass Spec 545(M+H).
EXAMPLE 206
2- (4-Methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-5- 2-(methyl-octyl-carbamoyl)-vinyl!-benzoic acid
In the same manner as described in Example 18, 188 mg (0.35 mmol) of the product of Example 205 provided 170 mg (93%) of the desired carboxylic acid as a white solid after trituration with Hexane/EtOAc (2:1). Electrospray Mass Spec 575(M+HCOOH--H).
EXAMPLE 207
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-5- 2-(methyl-octyl-carbamoyl)-vinyl!-benzamide
In the same manner as described in Example 23, 154 mg (0.29 mmol) of the product of Exauple 206 provided 45 mg (28%) of the desired hydroxamic acid as an off white solid. Electrospray Mass Spec 546(M+H).
EXAMPLE 208
5-(2-tert-Butoxycarbonyl-ethyl)-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid methyl ester
A mixture of 340 mg (0.71 mmol) of the product of Example 203 and 35 mg of 10% palladium on carbon in 15 ml of ethanol was hydrogenated on a Parr shaker for 2 hr. The resulting mixture was filtered through Celite and Magnesol to provide 325 mg (95%) of the desired product as a colorless gum. Electrospray Mass Spec 478(M+H).
EXAMPLE 209
5-(2-Carboxy-ethyl)-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 204, 206 mg (0.43 mmol) of the product of Example 208 provides 181 mg (100%) the desired product as colorless gum. Electrospray Mass Spec 420(M-H).
EXAMPLE 210
2- (4-Methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-5- 2-(methyl-octyl-carbamoyl)-ethyl!-benzoic acid methyl ester
In the same maimer as described in Example 205, 286 mg (0.68 mmol) of the product of Example 209 provides 362 mg (97%) of the desired product as a colorless gum. Electrospray Mass Spec 547(M+H).
EXAMPLE 211
2- (4-Methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-5- 2-(methyl-octyl-carbamoyl)-ethyl!-benzoic acid
In the same manner as described in Example 18, 340 mg (0.62 mmol) of the product of Example 210 provided 304 mg (92%) of the desired carboxylic acid as a pale yellow crystalline solid. Electrospray Mass Spec 533(M+H).
EXAMPLE 212
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-5- 2-(methyl-octyl-carbamoyl)-ethyl!-benzamide
To a slurry of 300 mg (0.56 mmol) of the product of Example 211 and 106 mg (0.78 mmol) of 1-hydroxybenzotriazole in 5 ml DMF was added 183 mg (0.95 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride and the reaction was stirred for 30 min at room temperature. Hydroxylamine hydrochloride (227 mg, 3.26 mmol) and 0.68 ml (4.89 mmol) of triethylamine and the reaction was sired for 18 hr. The resulting mixture was diluted with water and extracted with dichloromethane. The combined organics were washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel with 2% MeOH/CH 2 Cl 2 as the eluant to provide 190 mg (62%) of the desired hydroxamic acid as an off white solid. Electrospray Mass Spec 548(M+H).
EXAMPLE 213
5-(2-Dimethylcarbamoyl-vinyl)-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 203, 428.3 mg (1.0 mmol) of the roduct of Example 202 and 0.309 ml (3.0 mmol) of N,N-dimethylacrylamide provided 418 mg (93%) of the desired product as a colorless gum. Electrospray Mass Spec 447(M+H).
EXAMPLE 214
5-(2-Dimethylcarbamoyl-vinyl)-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid
In the same manner as described in Example 18, 418 mg (0.94 mmol) of the product of Example 213 provided 303 mg (75%) of the desired carboxylic acid as a white solid. Electrospray Mass Spec 477 (M+HCOOH--H).
EXAMPLE 215
5-(2-Dimethylcarbamoyl-vinyl)-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzamide
In te same manner as described in Example 212, 303 mg (0.70 mmol) of the product of Example 214 provided 268 mg (85%) of the desired hydroxamic acid as a white solid. Electrospray Mass Spec 448(M+H).
EXAMPLE 216
N-Ethyl-N-pyridin-4-ylmethyl-acrylamide
To a 0° C. solution of 0.835 ml (6.0 mmol) of 4-(ethylaminomethyl) pyridine and 1.05 ml (7.5 mmol) of triethylamine in 10 ml dichloomethane, was dropwise added 0.406 ml (5.0 mmol) of acryloyl chloride. The reaction mixture was warmed to room temperature and stilred for 18 hr. The resulting nmxture was washed with water and brne, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel with 3% MeOH/CH 2 Cl 2 as the eluant to provide 651 mg (68%) of the desired product as a yellow gum. Electrospray Mass Spec 191(M+H).
EXAMPLE 217
5- 2-(Ethyl-pyridin-4-ylmethyl-carbamoyl)-vinyl!-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzioc acid methyl ester
In the same manner as described in Example 203, 342.6 mg (0.80 mmol) of the product of Example 202 and 456.6 mg (2.4 mmol) of the product of Example 216 provided 405 mg (94%) of the desired product as a yellow gum. Electrospray Mass Spec 538(M+H).
EXAMPLE 218
5- 2-(Ethyl-pyridin-4-ylmethyl-carbamoyl)-vinyl!-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid
To a solution of 405 mg (0.75 numol) of the product of Example 217 in 8 ml of THF:MeOH:H 2 O (2:1:1) was added 126.4 mg (3.01 mmol) of lithium hydroxide monohydrate. The reaction mixture was heated to reflux for 18 hr and then concentrated in vacuo. The residue was diluted with water, neutralized with 3N HCl and extracted with dichloromethane. The combined organics were washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo to provide 222 mg (56%) of the desired carboxylic acid as a beige solid. Electrospray Mass Spec 524(M+H).
EXAMPLE 219
5- 2-(Ethyl-pyridin-4-ylmethyl-carbamoyl)-vinyl!-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzamide
In the same manner as described in Example 212, 214 mg (0.408 mmorl) of the product of Example 218 provided 156 mg (71%) of the desired hydroxamic acid, which was then dissolved in 2 ml of CH 2 Cl 2 and Red with 0.32 ml (0.32 mmol) of 1M HCl/Et 2 O. The resulting mixture was stirred for 1 hr at room tempure and concentrated in vacuo to provide 150 mg (64%) of the desired hydroxamic acid hydrochloride as a beige solid. Electrospray Mass Spec 539(M+H).
EXAMPLE 220
5-(2-tert-Butoxycarbonyl-vinyl)-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 203, 1.08 g (2.13 inmol) of the product of Example 89 provided 771 mg (65%) of the desired product as a brown oil. Electrospray Mass Spec 553(M+H).
EXAMPLE 221
5-(2-Carboxy-vinyl)-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 204, 750 mg (1.36 mmol) of the product of Example 220 provided 500 mg (60%) of the desired product. Electrospray Mass Spec 541(M+HCOOH--H)
EXAMPLE 222
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5- 2-(methyl-octyl-carbamoyl)-vinyl!-benzoic acid methyl ester
In the manner as described in Example 205, 270 mg (0.54 mmol) of the product of Example 221 provided 162 mg (48%) of the desired product as a colorless gum. Electrospray Mass Spec 622(M+H).
EXAMPLE 223
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5- 2-(methyl-octyl-carbamoyl)-vinyl!-benzoic acid
In the same manner as described in Example 218, 386 mg (0.62 mmol) of the product of Example 222 provided 274 mg (73%) of the desired carboxylic acid as a white crystalline solid. Electrospray Mass Spec 652(M+HCOOH--H).
EXAMPLE 224
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5- 2-(methyl-octyl-carbamoyl)-vinyl!-benzamide
In the same manner as described in Example 219, 261 mg (0.43 mmol) of the product of Example 223 provided 211 mg (75%) of the desired product as a beige solid. Electrospray Mass Spec 623(M+H).
EXAMPLE 225
5-(2-Dimethylcarbamoyl-vinyl)-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 203, 550.4 mg (1.0 mmol) of the product of Example 89 and 297.4 mg (3.0 mmol) of N,N-dimethylacrylamide provided 419 mg (80%) of the desired product as a white solid. Electrospray Mass Spec 524(M+H).
EXAMPLE 226
5-(2-Dimethylcarbamoyl-vinyl)-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid
In the same manner as described in Example 218, 404 mg (0.77 mmol) of the product of Example 225 provided 250 mg (64%) of the desired carboxylic acid as a pale yellow solid. Electrospray Mass Spec 508(M-H).
EXAMPLE 227
5-(2-Dimethylcarbamoyl-vinyl)-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzamide
In the same manner as described in Example 219, 230 mg (0.45 mmol) of the product of Example 226 provided 54 mg (20%) of the desired product as a yellow solid. Electrospray Mass Spec 525(M+H).
EXAMPLE 228
5- 2-(Ethyl-phenyl-carbamoyl)-vinyl!-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 203, 550.4 mg (1.0 mmol) of the product of Example 89 and 425 mg (2.43 mniol) of N-ethylacryianilide provided 392 mg (65%) of the desired product as a brown solid. Electrospray Mass Spec 600(M+H).
EXAMPLE 229
5- 2-(Ethyl-phenyl-carbamoyl)-vinyl!-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid
In the same manner as described in Example 218, 582 mg (0.97 mmol) of the product of Example 228 provided 404.7 mg (71%) of the desired carboxylic acid as a mustard solid. Electrospray Mass Spec 584(M-H).
EXAMPLE 230
5- 2-(Ethyl-phenyl-carbamoyl)-vinyl!-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzamide
In the same manner as described in Example 219, 402 mg (0.69 mmol) of the product of Example 229 provided 190 mg (43%) of the desired product as a beige solid. Electrospray Mass Spec 601(M+H).
EXAMPLE 231
5-(2-Diallylcarbamoyl-vinyl)-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 203, 550.4 mg (1.0 mmol) of the product of Example 89 and 453.6 mg (3.0 mmol) of N,N-diallylacrylamide provided 309 mg (53%) of the desired product as a yellow gum. Electrospray Mass Spec 576(M+H).
EXAMPLE 232
5-(2-Diallylcarbamoyl-vinyl)-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid
In a same manner as described in Example 218, 276 mg (0.48 mmol) of the product of Example 231 provided 149 mg (55%) of the desired carboxylic acid as a beige solid. Electrospray Mass Spec 562(M+H).
EXAMPLE 233
5-(2-Diallylcarbamoyl-vinyl)-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzamide
In the same manner as described in Example 219, 188 mg (0.34 mmol) of the product of Example 232 provided 134 mg (65%) of the desired product as a brown solid Electrospray Mass Spec 577(M+H).
EXAMPLE 234
5-Bromo-2-(dimethylamino-methyleneamino)-3-methyl-benzoic acid tert-butyl ester
A mixture of 5.0 g (21.7 mmol) of the product of Example 132 and 20.8 ml (86.9 mmol) of N,N-dimethylformamide di-t-butylacetal in 30 ml of toluene was heated to reflux for 2 hr. The reaction mixture was cooled to room tenperature, washed with water and brine, dried over MgSO 4 and concentrated in vacuo to provide 3.61 g (49%) of the desired product as an yellow oil. Electrospray Mass Spec 341(M+H).
EXAMPLE 235
2-Amino-5-bromo-3-methyl-benzoic acid tert-butyl ester
A mixture of 3.52 g (10.3 mmole) of the product of Example 234 and 6.12 g (44.94 mmol) of zinc chloride in 50 ml of absolute ethanol was heated to reflux for 18 hr. The reaction mixture was concentrated in vacuo and the residue was diluted with CH 2 Cl 2 and washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo to provide 2.48 g (84%) of the desired product as a pale brown liquid. Electrospray Mass Spec 286(M+H).
EXAMPLE 236
5-Bromo-2-(4-methoxy-benzenesulfonylamino)-3-methyl-benzoic acidtert-butyl ester
In the same manner as described in Example 1, 2.48 g (8.66 mmol) of the product of Example 235 provided 3.41 g (86%) of the desired product as a pale yellow oil. Electrospray Mass Spec 402(M-t-bu-H).
EXAMPLE 237
5-Bromo-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-aminol!-3-methyl-benzoic acid tert-butyl ester
In the same manner as described in Example 81, 3.15 g (6.9 mmol) of the product of Example 235 provided 2.6 g (69%) of the desired product as a white solid. Electrospray Mass Spec 547(M+H).
EXAMPLE 238
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5-(3-morpholin-4-yl-3-oxo-propenyl)-benzoic acid tert-butyl ester
In the same manner as described in Example 203, 547.5 mg (1.0 mmol) of the product of Example 237 and 423 mg (3.0 mmol) of N-acryloylmorpholine provided 542 mg (89%) of the desired product as a pale yellow gum. Electrospray Mass Spec 608(M+H).
EXAMPLE 239
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5-(3-morpholin-4-yl-3-oxo-propenyl)-benzoic acid
In the same manner as described in Example 204, 492 mg (0.809 mmol) of the product of Example 238 provided 464 mg (86%) of the desired product as a pale yellow solid. Electrospray Mass Spec 552(M+H).
EXAMPLE 240
N-Hydroxy-2- (4-methoxy-benzenesulfonyl pyridin-3-ylmethyl-amino!-3-methyl-5-(3-morpholin-4-yl-3-oxo-propenyl)-benzamide
In the same manner as described in Example 219, 150 mg (0.27 mmol) of the product of Example 239 provided 114 mg (25%) of the desired product as a cream solid. Electrospray Mass Spec 567(M+H).
EXAMPLE 241
2'-Formyl-4- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-biphenyl-3-carboxylic acid methyl ester
To 5 ml of degassed ethylene glycol dirncthyl ether, was added 505.4 mg (1.0 mmol) of the product of Example 89, 165 mg (1.1 mmol) of 2-formylbenzene boronic acid, 58 mg (0.05 mmol) of tetrakis(triphenylphosphine)palladium and 1 ml (2.0 mmol) of 2M aqueous Na 2 CO 3 and the mixture ws heated to reflux under nitrogen for 18 hr. The reaction was cooled to room temperature, diluted with ethyl acetate, washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel with EtOAc/Hexane (1:1) as eluant to provide 499 mg (94%) of the desired product as an yellow solid. Electrospray Mass Spec 531 (M+H).
EXAMPLE 242
2'-Formyl-4- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-biphenyl-3-carboxylic acid
In the same manner as described in Example 218, 478 mg (0.9 mmol) of the product of Example 241 provided 392 mg (84%) of the desired carboxylic acid as a pale yellow solid. Electrospray Mass Spec 515 (M-H).
EXAMPLE 243
2'-(Hydroxyimino-methyl)-4- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-biphenyl-3-carboxylic acid hydroxyamide
In the same manner as described in Example 219, 380 mg (0.74 mmol) of the product of Example 242 provided 310 mg (53%) of the desired product as a cream solid. Electrospray Mass Spec 547 (M+H).
EXAMPLE 244
3'-Formyl-4- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-biphenyl-3-carboxylic acid methyl ester
In the same manner as described in Example 241, 505.4 mg (1.0 mmol) of the product of Example 89 and 165 mg (1.1 mmol) of 3-formylbenzeneboronic acid provided 530 mg (100%) of the desired product as a pale yellow crystal. Electrospray Mass Spec 531 (M+H).
EXAMPLE 245
3'-Formyl-4- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-biphenyl-3-carboxylic acid
In the same manner as described in Example 218, 500 mg (0.96 nmnol) of the product of Example 244 provided 214 mg (43%) of the desired carboxylic acid as a white solid. Electrospray Mass Spec 515 (M-H).
EXAMPLE 246
3'-(Hydroxyimino-methyl)-4- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-biphenyl-3-carboxylic acid hydroxyamide
In the same manner as described in Example 219, 196 mg (0.38 mmol) of the product of example 245 provided 176 mg (80%) of the desired product as a cream solid. Electrospray Mass Spec 547 (M+H).
EXAMPLE 247
4'-Formyl-4- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-biphenyl-3-carboxylic acid methyl ester
In the same manner as described in Example 241, 505.4 mg (1.0 mmol) of the product from Example 89 and 165 mg (1.1 mmol) of 4-formylbenzene boronic acid provided 519 mg (98%) of the desired product as a pale yellow solid. Electrospray Mass Spec 531 (M+H).
EXAMPLE 248
4'-Formyl-4- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-biphenyl-3-carboxylic acid
In the same manner as described in Example 218, 486 mg (0.92 mmol) of the product of Example 247 provided 362 mg (76%) of the desired product as a white solid. Electrospray Mass Spec 515 (M-H).
EXAMPLE 249
4'-(Hydroxyimino-methyl)-4- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-biphenyl-3-carboxylic acid hydroxyamide
In the same manner as described in Example 219, 320 mg (0.62 mmol) of the product of Example 248 provided 166 mg (49%) of the desired product as a cream solid. Electrospray Mass Spec 547 (M+H).
EXAMPLE 250
4- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-240-triftuoromethyl-biphenyl-3-carboxylic acid methyl ester
In the same manner as described in Example 241, 505.4 mg (1.0 mmol) of the product of Example 89 and 244 mg (1.1 mmol) of 2-trifluoromethylbenzene boronic acid provided 559 mg (98%) of the desired product as a pale yellow gum. Electrospray Mass spec 571 (M+H).
EXAMPLE 251
4- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-2'-trifluoromethyl-biphenyl-3-carboxylic acid
In the same manner as desctibed in Example 218, 541 mg (0.95 mmol) of the product of Example 250 provided 475 mg (90%) of the desired carboxylic acid as a white solid. Electrospray Mass Spec 557 (M+H).
EXAMPLE 252
4- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-2'-trifluoromethyl-biphenyl-3-carboxylic acid hydroxyamide
In the same manner as described in Example 61, 447 mg (0.803 mmol) of the product of Example 251 provided the desired product, which was dissolved in 3 ml of dichlmethane and 3m1 of methanol and treated with 0.76 ml (0.76rmol) of 1M HCl/Et 2 O. The reacion mixture was stirred for 1 hr at room temperature and concentrated in vacuo to provide 373 mg (76%) of the desired product. as a beige solid. Electrospray Mass Spec 572 (M+H).
EXAMPLE 253
5-Furan-2-yl-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid methyl ester
In the same manner as described in Exanple 241, 505.4 mg (1.0 mmol) of the product of Exaaaple 89 and 123 mg (1.1 mmol) of furan-2-boronic acid provided 432 mg (88%) of the desired product as a pale yellow solid. Electrospray Mass Spec 493 (M+H).
EXAMPLE 254
5-Furan-2-yl-2- (4-metboxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid
In the same manner as described in Example 218, 419 mg (0.85 mmol) of the product of Example 253 provided 227 mg (47%) of the desired carboxylic acid as a white solid after trituration with ether. Electrospray Mass Spec 477 (M-H).
EXAMPLE 255
5-Furan-2-yl-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzamide
In the same manner as described in Example 219, 220 mg (0.46 mmol) of the product of Example 254 provided 185 mg (76%) of the desired product as a cream solid. Electrospray Mass Spec 494 (M+H).
EXAMPLE 256
5-(3-Formyl-thiophen-2-yl)-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 241, 505.4 mg (1.0 mmol) of the product of Example 89 and 343.2 mg (2.2 mmol) of 3-formylthiophene-2-boronic acid provided 379 mg (71%) of the desired product as a pale yellow solid. Electrospray Mass Spec 537 (M+H).
EXAMPLE 257
5-(3-Formyl-thiophen-2-yl)-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid
In the same manner as described in Example 218, 364 mg (0.68 mmol) of the product of Example 256 provided 229 mg (65%) of the desired carboxylic acid as a pale yellow solid. Electrospray Mass Spec 521 (M-H).
EXAMPLE 258
N-Hydroxy-5- 3-(hydroxyimino-methyl)-thiophen-2-yl!-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzamide
In the same manner as described in Example 219, 220 mg (0.42 mmol) of the product of Example 257 provided 168 mg (68%) of the desired product as a cream solid. Electrospray Mass Spec 553 (M+H).
EXAMPLE 259
5-(5-Chloro-thiophen-2-yl)-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 241, 505 mg (1.0 mmol) of the product of Example 89 and 357 mg (2.2 mmol) of 5-chlorothiophene-2-boronic acid provided 332 mg (61%) of the desired product as an yellow solid. Electrospray Mass Spec 543 (M+H).
EXAMPLE 260
5-(5-Chloro-thiophen-2-yl)-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid
In the same manner as described in Example 218, 312 mg (0.58 mmol) of the product of Example 259 provided 277 mg (91%) of the desired carboxylic acid as a pale yellow solid. Electrospray Mass Spec 527 (M-H).
EXAMPLE 261
5-(5-Chloro-thiophen-2-yl)-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzamide
In the same manner as described in Example 219, 277 mg (0.524 mmol) of the product of Example 260 provided 135 mg (44%) of the desired product as a pale yellow solid. Electrospray Mass Spec 544 (M+H).
EXAMPLE 262
5-(5-Acetyl-thiophen-2-yl)-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 241, 505.4 mg (1.0 mmol) of the product of Example 89 and 374 mg (2.2 mmol) of 5-acetylthiophene-2-boronic acid provided 525 mg (95%) of the desired product as a cream colored solid. Electrospray Mass Spec 551 (M+H).
EXAMPLE 263
5-(5-Acetyl-thiophen-2-yl)-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid
In the same manner as described in Example 218, 500 mg (0.9 mmol) of the product of Example 262 provided 390 mg (81%) of the desired carboxylic acid as a pale yellow solid. Electrospray Mass Spec 535 (M-H).
EXAMPLE 264
5-(5-Acetyl-thiophen-2-yl)-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzamide
In the same manner as described in Example 219, 400 mg (0.75 mmol) of the product of Example 263 provided 226 mg (52%) of the desired product as a white solid. Electrospray Mass Spec 552 (M+H).
EXAMPLE 265
2- Benzyl-(4-metboxy-benzenesulfonyl)-amino!-3-methyl-5-vinyl-benzoic acid methyl ester
In the same manner as described in Example 139, 728 mg (1.44 mmol) of the product of Example 11 and 0.552 ml (2.0 mmol) of vinyltributyltin provided 430 mg (66%) of the desired product as a white solid. Electrospray Mass Spec 452 (M+H).
EXAMPLE 266
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-methyl-5-vinyl-benzoic acid
In the same manner as described in Example 18, 160 mg (0.35 mmol) of the product of Example 265 provided 133 mg (85%) of the desired carboxylic acid as a white solid. Electrospray Mass Spec 436 (M-H).
EXAMPLE 267
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-methyl-5-vinyl-benzamide
In the same manner as described in Example 23, 120 mg (0.27 mmol) of the product of Example 266 provided 63.4 mg (51%) of the desired hydroxamic acid as a white solid. Electrospray Mass Spec 453 (M+H).
EXAMPLE 268
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-formyl-3-methyl-benzoic acid methyl ester
To a solution of 2.21 g (4.89mmole) of the product of Example 265 in 20 ml of dioxane:H2O (3:1) was added 0.3 ml of a 2.5 weight % solution of osmium tetroxide in tbutanol and the reaction was stirred until the solution turned dark brown. Then 2.09 g (9.78 mmol) of sodium periodate was added portionwise over a period of 20 min. The resulting mixture was stirred for 1.5 hr, diluted with ether, washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo to provide 1.73 g (78%) of the desired product as a white solid after trituration with ether. Electrospray Mass Spec 454 (M+H).
EXAMPLE 269
4- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-methyl-isophthalic acid 3-methyl ester
To a solution of 317 mg (0.7 mmol) of the product of Example 268 and 102 mg (1.05 mmol) of sulfamic acid in 40 ml of water:THF (3:1) was added 98 mg (1.08 mmol) of sodium chlorite. The resulting mixture stirred for 2 hr, diluted with ether, washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo to provide 325 mg (99%) of the desired carboxylic acid as a white solid. Electrospray Mass Spec 468 (M-H).
EXAMPLE 270
4- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-methyl-isophthalic acid
In the same manner as described in Example 18, 325 mg (0.7 mmol) of the product of exanmple 169 provided 224.3 mg (70%) of the desired product as a white solid. Electrospray Mass Spec 454 (M-H).
EXAMPLE 271
4- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N(1),N(3)-dihydroxy-5-methyl-isophthalamide
In the same manner as described in Example 23, 210 mg (0.46 mmol) of the product of Example 270 provided 160 mg (72%) of the desired product as a cream solid. Electrospray Mass Spec 486 (M+H).
EXAMPLE 272
4- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N(1),N(3)-dihydroxy-5-methyl-isophthalamide di-sodium salt
To a solution of 100 mg (0.206 mmol) of the product of Example 271 in 2 ml of methanol was added 0.412 ml (0.412 mmol) of 1N NaOH andthe reaction was stirred at room temperature for 2 hr. The reaction mixture was concentrated in vacuo, and the residue was triturated with ether to provide 109 mg (100%) of the desired product as a pale yellow solid Electrospray Mass Spec 486 (M+H).
EXAMPLE 273
2-(4-Methoxy-benzenesulfonylamino)-3-methyl-5-vinyl-benzoic acid methyl ester
In the same manner as described in Example 139, 700 mg (1.69 mmol) of the product of Example 10 and 0.73 ml (2.5 mmol) of vinyltributyltin provided 500 mg (82%) of the desired product as a white solid. Electrospray Mass Spec 362 (M+H).
EXAMPLE 274
5-Ethyl-2-(4-methoxy-benzenesulfonylamino)-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 208, 479 mg (1.33 mmol) of the product of Example 273 provided 480 mg (100%) of the desired product as a white solid. Electrospray Mass Spec 364 (M+H).
EXAMPLE 275
5-Ethyl-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid methyl ester
In the same manner as described in Example 81, 455 mg (1.25 mmol) of the product of Example 274 provided 544 mg (96%) of the desired product as a pale yellow oil. Electrospray Mass Spec 455 (M+H).
EXAMPLE 276
5-Ethyl-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid
In the same manner as described in Example 218, 496 mg (1.09 mmol) of the product of Example 275 provided 345 mg (72%) of the desired carboxylic acid as a beige solid. Electrospray Mass Spec 441 (M+H).
EXAMPLE 277
5-Ethyl-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzamide
In the same manner as described in Example 23, 320 mg (0.73 mmol) of the product of Exanple 276 provided 166 mg (50%) of the desired hydroxamic acid. The hydroxamic acid was then dissolved in 4 ml of dichloromethane and 0.1 ml of methanol and 0.4 ml (0.4 mmol) of 1M HCl/ether was added. The reaction mixture was stirred for 1 hr and concentrated in vacuo. The residue was triturated with ether to provide 177 mg (98%) of the desired product as a cream solid. Electrospray Mass Spec 456 (M+H).
EXAMPLE 278
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-hydroxymethyl-3-methyl-benzoicacid methyl ester
To a mixture of 907 mg (2.0 mmol) of the product of Example 268 in 50 ml of MeOH:THF (4:1) was added sodium borohydride. The reaction was then stilred at room temperature for 30 min and concentrated in vacuo. The residue was dissolved in dichloromethane, washed with 5% HCl and brine, dried over MgSO 4 , filtered and concentrated in vacuo to provide 872 mg (96%) of the desired product as a white crystalline solid. Electrospray Mass Spec 456 (M+H).
EXAMPLE 279
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-bromomethyl-3-methyl-benzoic acid methyl ester
To a 0° C. solution of 1.08 g (2.37 mmol) of the product of Example 278 and 983 mg (2.96 mmol) of carbon tetrabromide in 24 ml of dichloromethane was added 933 mg (3.55 mmol) of triphenyl phosphine. The resulting mixture was stirred for 15 min and then concentrated in vacu. The residue was chromatographed on silica gel using EtOAc:Hexane (1:6) as eluant to provide 1.1 g (96%) of the desired product as a white crystalline solid. Electrospray Mass Spec 520 (M+H).
EXAMPLE 280
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-diethylaminomethyl-3methyl-benzoic acid methyl ester
A solution of 518.4 mg (1.0 mmole) of the product of Example 279, 0.5 ml (4.8 mmol) of diethylamine and 0.172 ml (2.0 mmol) of pyridine in 10 ml of dichloromethane was stired at room temperature for 18 hr. The resulting mixture washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel with 2% MeOH/CH 2 Cl 2 as eluant to provide 425 mg (83%). Electrospray Mass Spec 511 (M+H).
EXAMPLE 281
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-diethylaminomethyl-3-methyl-benzoic acid
In the same manner as described in Example 218, 400 mg (0.78 mmol) of the product of Example 280 provided 324 mg (85%) of the desired carboxylic acid as a white solid. Electrospray Mass Spec 497 (M+H).
EXAMPLE 282
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-diethylaminomethyl-N-hydroxy-3-methyl-benzamide
In the same manner as described in Example 219, 324 mg (0.65 mmol) of the product of example 281 provided 162 mg (45% 0 of the desired product as a beige solid. Electrospray Mass Spec 512 (M+H).
EXAMPLE 283
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5-pyridin-3-yl-benzoic acid methyl ester
In the same manner as described in Example 139, 505 mg (1.0 mmol) of the product of Example 89 and 515 mg (1.4 mmol) of 3-(tributylstannyl)pyridine provided 437 mg (87%) of the desired product as a pale yellow solid. Electrospray Mass Spec 504 (M+H).
EXAMPLE 284
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5-pyridin-3-yl-benzoic acid
In the smae manner as described in Example 218, 422 mg (0.84 mmol) of the product of Example 283 provided 410 mg (100%) of the desired carboxylic acid as a cream solid. Electrospray Mass Spec 490 (M+H).
EXAMPLE 285
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5-pyridin-3-yl-benzamide
In the same manner as described in Example 219, 420 ng (0.85 mmol) of the product of Example 284 provided 160 mg (33%) of the desired product as a pinkish solid. Electrospray Mass Spec 505(M+H).
EXAMPLE 286
2-Amino-3,6-dimethyl-benzoic acid benzyl ester
A mixture of 940 mg (5.73 mmol) of 2-amino-3,6-dimethylbenzoic acid, 0.750 ml (6.3 mmol) of benzyl bromide, 1.04 g (7.5mmole) of potassium carbonate and 40 mg (0.27mmole) of soium iodide in 20 ml of acetone was heated to reflux for 20 hr. The resulting mixture was then concentrated in vacuo and the residue was chronatoghed with EtOAc/Hexane (1:50) as eluant to provide 697 mg (48%) of the desired product as a yellow oil. Electrospray Mass Spec 256 (M+H).
EXAMPLE 287
2-(4-Methoxy-benzenesulfonylamino)-3,6-dimethyl-benzoic acidbenzyl ester
In the same manner as described in Example 1,971 mg (3.8 mmol) of the product of Example 286 provided 1.415 g (87%) of the desired product as a cream solid after trituration with Ether/Hexane(1:1). Electrospray Mass Spec 426 (M+H).
EXAMPLE 288
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3,6-dimethyl-benzoic acid benzyl ester
In the same manner as described in Example 9, 321 mg (0.754 mmol) of the product of Example 287 provided 356 mg (92%) of the desired product as a white solid after trituration with hexane. Electrospray Mass Spec 516 (M+H).
EXAMPLE 289
N-Benzyl-N-(2-hydroxymethyl-3,6-dimethyl-phenyl)-4-methoxy-benzenesulfonamide
To a slurry of 21 lmg (5.04 mmol) of lithium aluminum hydride in 6 ml of dry THF under nitrogen, was added dropwise a solution of 649 mg (1.26 mmol) of the product of Example 288 in 6 ml of dry THF. The reaction mixture was stirred for 3 hr and then sodium sulfate pentahydrate was slowly added until sizzling stopped and thick solid formed. The solid was filtered and the filtrate was concentrated in vacuo to provide 454 mg (87%) of the desired product as a white solid after trituration with hexane. Electrospray Mass Spec 412 (M+H).
EXAMPLE 290
N-Benzyl-N-(2-formyl-3,6-dimethyl-phenyl)-4-methoxy-benzenesulfonamide
To a solution of 438.7 mg of the product of Example 289 in 20 ml of acetone was added 5.33 ml (10.07 mmol) of Jones reagent and the reaction was stirred at room temperature for 18 hr. The resulting mixture was concentrated in vacuo and the residue was diluted with dichloromethane, washed with water and brine, dried over MgSO 4 , filtered and concnentrated in vacuo. The residue was triturated with hexane to provide 396 mg (91%) of the desired product as a white solid. Electrospray Mass Spec 410 (M+H).
EXAMPLE 291
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3,6-dimethyl-benzoic acid
In the same manner as described in Example 269, 378 mg (0.92 mmol) of the product of Example 290 provided 260 mg (66%) of the desired carboxylic acid as a white solid. Electrospray Mass Spec 426 (M+H).
EXAMPLE 292
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3,6-dimethyl-benzamide
In the same manner as described in Example 23, 255 mg (0.6 mmol) of the product of Example 291 provided 206 mg (78%) of the desired product as a white solid. Electrospray Mass Spec 441 (M+H).
EXAMPLE 293
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3,6-dimethyl-benzoic acid benzyl ester
In the same manner as described in Example 81, 1.415 g (3.33 mmol) of the product of example 287 provided 1.02 mg (59%) of the desired product as a white solid after trituration with ether. Electrospray Mass Spec 517 (M+H).
EXAMPLE 294
N-(2-Hydroxymethyl-3,6-dimethyl-phenyl)-4-methoxy-N-pyridin-3-ylmethyl-benzenesulfonamide
In the same manner as described in Example 289, 993 mg (1.92 mmol) of the product of Example 293 provided 633 mg (80%) of the desired product as a yellow oil. Electrospray Mass Spec 413 (M+H).
EXAMPLE 295
N-(2-Formyl-3,6-dimethyl-phenyl)-4-methoxy-N-pyridin-3-ylmethyl-benzenesulfonamide
In the same manner as described in Example 290, 633 mg (1.54 mmol) of the product of Example 294 provided 438 mg (787%) of the desired product as a yellow solid. Electrospray Mass Spec 411 (M+H).
EXAMPLE 296
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3,6-dimethyl-benzoic acid
In the same manner as described in Example 269, 438 mg (1.07 mmol) of the product of Example 295 provided 345 mg (76%) of the desired carboxylic acid as an off white solid. Electrospray Mass Spec 425 (M-H).
EXAMPLE 297
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3,6-dimethyl-benzamide
In the same manner as described in Example 252, 130 mg (0.31 mmol) of the product of Example 296 provided 100 mg (74%) of the desired hydroxamic acid. A sample of 235 mg (0.53 nmol) of this product provided 229 mg (90%) of the desired hydroxamic acid hydrochloride as a cream colored solid after trituration with ether. Electrospray Mass is Spec 442 (M+H).
EXAMPLE 298
2-(4-Methoxy-benzenesulfonylamino)-3-methyl-5- 3-(5-methyl-furan-2-yl)-isoxazol-5-yl!-benzo acid methyl ester
To a solution of 146.6 mg (1.1 mmol) of N-chlorosuccinimide and 0.006 ml of pyridine in 3.0 ml of chloroform under nitrogen was added 348.2 mg (1.09 mmol) of 5-methyl-fiuran-2-caboxaldehyde oxime at room temperature. The reaction mixture was stirred for 30 min and 392 mg (1.09 mmol) of 5-ethynyl-2-(4-methoxybenzene-sulfonylamino)-3-methyl-benzoic acid methyl ester was added in one portion followed by the dropwise addition of 0.16 ml (1.15 mmol) of triethylamine over a period of 1 hr. The resulting mixture was stirred at room temperature for 18 hr, diluted with dichloromethane, washed with water and brine, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel with EtOAc/Hexane (1:9) as eluant to provide 313 mg (60%) of the desired product. as a white solid. Electrospray Mass Spec 483 (M+H).
EXAMPLE 299
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5- 3-(5-methyl-furan-2-yl)-isoxazol-5-yl!-benxoic acid methyl ester
In the same manner as described in Example 81, 305 mg (6.3 mmol) of the product of Example 298 provided 240 mg (66%) of the desired product as a colorless gum. Electrospray Mass Spec 574 (M+H).
EXAMPLE 300
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5- 3-(5-methyl-furan-2-yl)-isoxazol-5-yl!-benzoic acid
In the same manner as described in Example 218, 234 mg (0.408 mmol) of the product of Example 299 provided 149 mg (65%) of the desired carboxylic acid as a pale yellow solid. Electrospray Mass Spec 560 (M+H).
EXAMPLE 301
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5- 3-(5-methyl-furan-2-yl)-isoxazol-5-yl-benzamide
In the same manner as described in Example 219, 141 mg (0.25 mmol) of the product of Example 300 provided 30 mg (19%) of the desired product as a brownish solid. Electrospray Mass Spec 575 (M+H).
EXAMPLE 302
2- Benzyl-(4-ethoxy-benzenesulfonyl)-amino!-N-hydroxy-3,5-dimethyl-benzamide
The product of Example 65 (2.0 g, 4.68 mmol) is reacted with ethyl alcohol according to the procedure of Example 73 to give 0.461 g (21%) of the p-ethoxybenzene sulfonamide-ester.
The sulfonaride-ester (0.440 g, 0.941 mmol) is hydrolyzed according to the procedure of Example 18 to give 0.318 g (77%) of the carboxylic acid.
The carboxylic acid (0.290 g, 0.650 mmol) is converted into its acid chlorde followed by reaction with hydroxylamine according to the procedure of Example 23 to give 0.092 g (31%) of the hydroxamate. Electrospray Mass Spec: 455.3 (M+H)+.
EXAMPLE 303
2- Benzyl-(4-propoxy-benzenesulfonyl)-amino!-N-hydroxy-3,5-dimethyl-benzamide
The product of Exanple 65 (1.0 g, 2.339 mmol) is reacted with n-propanol accoding to the procedure of Example 73 to give 0.456 g (46%) of the para-n-propoxybenzene sulfonamide-ester.
The sulfonamideester (0.486 g, 0.980 mmol) is hydrolyzed according to the procedure of Example 18 to give 0.217 g (49%) of the carboxylic acid.
The carboxylic acid (0.190 g, 0.419 mmol) is converted into its acid chloride followed by reaction with hydroxylamine according to the procedure of Example 23 to give 0.104 g (53%) of the hydroxamate. Electrospray Mass Spec: 469.0 (M+H)+.
EXAMPLE 304
2- Benzyl-(4-isopropoxy-benzenesulfonyl)-amino!-N-hydroxy-3,5-dimethyl-benzamide
The product of Example 65 (2.0 g, 4.68 mmol) is reacted with isopropanol according to the procedure of Example 73 to give 0.706 g (30%) of the para-n-propoxybenzene sulfonamide-ester.
The sulfonamide-ester (0.400 g, 0.827 mmol) is hydrolyzed according to the procedure of Example 18 to give 0.180 g (48%) of the carboxylic acid.
The carboxylic acid (0.113 g, 0.331 mmol) is converted into its acid chloride followed by reaction with hydroxylamine according to the procedure of Example 23 to give 0.056 g (36%) of the hydroxamate. Electrospray Mass Spec: 468.9 (M+H)+.
EXAMPLE 305
5-Bromo-2-(4-fluoro-benzenesulfonylamino)-3-methyl-benzoic acid
By following the procedure of Example 134 the product of Example 133 and 4-flurobenzenesulfonyl chloride provides 5-bromo-2-(4-fluoro-benzenesulfonylamino)-3methyl-benzoic acid as a yellow solid in 36% yield. Electrospray Mass Spec: 386.0 (M-H)-
EXAMPLE 306
Benzyl-(4-fluoro-benzenesulfonyl)-amino!-5-bromo-3-methyl-benzoic acid benzyl ester
To a solution of 0.25 g (0.687 mmol) of the product of Example 305 in 5.0 mL of DMF was added 0.23 mL (1.923 mmol) of benzyl bromide and 0.06 g (1.511 mmol) of 60% sodium hydride. The reaction mixture was stirred for 18 h at room temperure and then diluted with ether, washed with water, dried over MgSO 4 , filtered and concentreted in vacuo. The resulting residue was chromatographed on silica gel eluting with EtOAc/Hxanes (1:10) to provide 0.324 g (82%) of the product as a colorless oil. Electrospray Mass Spec: 568.1 (M+H)+.
EXAMPLE 307
2- Benzyl-(4-benzyloxy-benzenesulfonyl)-amino!-5-bromo-3-methyl-benzoic acid
By following the procedure of Example 73, 0.284 g (0.493 mmol) of the product of Example 306 gives 0.185 g (66%) of the desired product as a white solid. Electrospray Mass Spec: 565.9 (M-H)-.
EXAMPLE 308
2- Benzyl-(4-benzyloxy-benzenesulfonyl)-amino!-5-bromo-N-hydroxy-3-methyl-benzamide
By following the procedure of Example 23, 0.168 g (0.297 mmol) of the product of Example 307 gives 0.131 g (76%) of the desired product as a white solid. Electrospray Mass Spec: 581.0 (M+H)+.
EXAMPLE 309
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-morpholin-4-ylmethyl-benzamide
Following the procedure of Example 189, the product of Example 188 (0.50 g, 1.168 mmol) and morpholine gives 0.325 g (64%) of the benzylic amine-ester.
Following the procedure of Example 190, 0.291 g (0.670 mmol) of the ester is then hydrolyzed to give 0.286 g (100%) of the carboxylic acid.
Following the procedure of Example 23, 0.229 g (0.536 mmol) of the carboxylic acid gives 0.186 g of the hydroxamic acid as a white solid. The hydroxamate is dissolved in 4 mL of dichloromeane and 0.2 mL of methanol and 0.85 mL of 1.0M HCl in ether is added. The reaction is stieed at room temperature for 1 h, diluted with ether and the resulting solid is collected by filtration and dried in vacuo to give 0.139 g of the hydroxamate-amine salt as a white solid. Electmspray Mass Spec: 435.9 (M+H)+.
EXAMPLE 310
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-pyrrolidin-1-ylmethyl-benzamide
Following the procedure of Example 189, the product of Example 188 (0.50 g, 1.168 mmol) and pyrrolidine gives 0.327 g (69%) of the benzylic amine-ester.
Following the procedure of Example 190, 0.307 g (0.734 mmol) of the ester is then hydrolyzed to give 0.302 g (100%) of the carboxylic acid.
Following the procedure of Example 309, 0.251 g (0.610 mmol) of the carboxylic acid gives 0.127 g of the hydroxamic acid-amine salt as a white solid. Electrospray Mass Spec: 419.9 (M+H)+.
EXAMPLE 311
N-Hydroxy-3-imidazol-1-ylmethyl-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-benzamide
Following the procedure of Example 189, the product of Example 188 (0.75 g, 1.752 mmol) and imidazole gives 0.441 g (61%) of the benzylic amine-ester.
Following the procedure of Example 190, 0.435 g (1.048 mmol) of the ester is then hydrolyzed to give 0.308 g (72%) of the carboxylic acid.
Following the procedure of Example 309, 0.261 g (0.640 mmol) of the carboxylic acid gives 0.154 g of the hydroxamic acid-amine salt as a white solid. Electrospray Mass Spec: 416.9 (M+H)+.
EXAMPLE 312
5-Bromo-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-(4-methyl-piperazin-1-ylmethyl)-benzoic acid methyl ester
To a solution of 3.0 g (7.01 mmol) of the product of Example 202 in 170 mL of carbon tetrachloride was added 1.56 g (8.76 mmmol) of N-bromosuccinimide and the mixture was heated to reflux while irradiated by a sunlamp for 3 h. The resulting mixture was cooled, washed with water, dried over MgSO 4 , filtered and concentrated in vacuo.
To a solution of 0.477 g (0.941 mmol) of the resulting benzylic bromide in 5.0 mL of DMF was added 0.115 mL (1.035 nmiol) of N-methylpiperazine and 0.389 g (2.822 mmol) of potassium carbonate. The reaction mixture was then stirred overnight at room temperature and then diluted with ether, washed with water, dried over Na 2 SO 4 , filtered and concentrated in vacuo. The resulting residue was chromatographed on silica gel eluting with chloroform/methanol (9:1) to provide 0.29 g (59%) of the product as a brown oil. Electospray Mass Spec: 526.1 (M+H)+.
EXAMPLE 313
5-B romo-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-(4-methyl-piperazin-1-ylmethyl)-benza
Following the prcedure of Example 190, 0.25 g (0.475 mmol) of the product of Example 312 gives 0.475 g (100%) of the desired carboxylate salt as a white solid.
Following the procedure of Example 309 the caiboxylate is converted into the corresponding hydroxamic acid-amine salt, isolated as a white solid. Electrospray Mass Spec: 527.1 (M+H)+.
EXAMPLE 314
5-Bromo-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-methylamino!-3-pyrrolidin-1-ylmethyl-benzamide
Following the procedure of Example 312, the product of Example 202 and pyrrodine gives the benzylic amine-ester.
Following the procedure of Example 190 the ester is hydrolyzed to the corresponding carboxylate.
Following the procedure of Example 309 the carboxylate is converted into the corresponding hydroxamic acid-amine salt, isolated as a tan solid. Electrospray Mass Spec: 498.0 (M+H)+.
EXAMPLE 315
2- (4-Methoxy-benzenesulfonyl)-(tert-butoxycarbonyl)-amino!-3-methyl-benzoic acid methyl ester
To a solution of 2.5 g (7.463 mmol) of the product of Example 3 in 10 mL of DMF and 6.0 mL of pyridine was added 1.95 g (8.955 mmol) of di-t-butyl dicarbonate and 0.228 g (1.866 mmol) of 4-dimethylaminopyridine. The resulting mixture was stirred overnight at room care and then diluted with ether, washed with 5% HCl solution, water and 1N sodium hydroxide solution. The organics were then dried over MgSO 4 , filtered and concentrated in vacuo. The residue was triturated with ether/hexanes (1:1) to give 3.2 g (98%) of the product as a white solid. Electrospray Mass Spec: 436.0 (M+H)+.
EXAMPLE 316
2- (4-Methoxy-benzenesulfonyl)-(tert-butoxycarbonyl)-amino!-3-(pyrrolidin-1-ylmethyl)-benzoic acid methyl ester
To a solution of 3.05 (7.011 mmol) of the product of Example 315 in 165 mL of carbon tetrachloride was added 1.498 g (8.414 mmol) of N-bromosuccinimide and the mixture was heated to reflux while irradiated by a sunlamp for 3 h. The resulting mixture was cooled, washed with water, dried over MgSO 4 , filtered and concentrated in vacuo.
To a solution of the resulting benzylic bromide in 30.0 mL of DMF was added 0.644 mL (7.71 mmol) of pyirolidine and 2.90 g of potassium carbonate. The raction mixture was then stirred overnight at room temperature and then diluted with ether, washed with water, dried over Na 2 SO 4 , filtered and concentrated in vacuo. The resulting residue was chromatographed on silica gel eluting with chloroform/methanol (9:1) to provide 2.076 g (59%) of the product as a.white solid. Electrospray Mass Spec: 505.2 (M+H)+.
EXAMPLE 317
2-(4-Methoxy-benzenesulfonylamino)-3-pyrrolidin-1-ylmethyl-benzoic acid methyl ester
To a solution of the product of example 316 in 10 mL of dichloromethane was added 10.0 mL of trifluoroacetic acid. The resulting solution was stirred at room temperature for 1 h and then concentrated in vacuo. The resulting residue was diluted with ether washed with saturated sodium bicarbonate solution, dried over Na 2 SO 4 , filtered and concentrated in vacuo. The residue was then triturated with ether to provide 0.93 g (57%) of the product as a pale yellow solid. Electrospray Mass Spec: 405.1 (M+H)+.
EXAMPLE 318
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-pyrrolidin-1-ylmethyl-benzoic acid methyl ester
By following the procedure of Example 45, 0.80 g (1.98 mmol) of the product of Example 317 gives 0.804 g (82%) of the product as a brown solid. Electrospray Mass Spec: 496.5 (M+H)+.
EXAMPLE 319
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-pyrrolidin-1-ylmethyl-benzoic acid
To a solution of 0.754 g (1.523 mmol) of the product of Example 318 in 15 mL of THF/Methanol (1:1) was added 7.6 mL of 1.0N sodium hydroxide solution. The resulting mixture was heated to reflux for 15 h and then concentrated in vacuo. The residue was diluted with water, neutralized with 5% HCl solution and exited with dichloromethane. The organics were dried over Na 2 SO 4 , filtered and concentrated in vacuo to provide 0.496 g (67%) of the product as a tan solid. Electrospray Mass Spec: 482.5 (M+H)+.
EXAMPLE 320
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-pyrrolidin-1-ylmethyl-benzamide
By following the procedure of Example 61 the product of Example 319 gives 0.174 g of the hydroxamic acid as a tan solid. Electrospray Mass Spec: 497.5 (M+H)+.
EXAMPLE 321
3-Formyl-2-(4-methoxy-benzenesulfonylamino)-benzoic acid methyl ester
To a solution of 1.0 g (2.985 mmol) of the product of Example 3 in 100 mL of carbon tetrachloride was added 0.20 g of dibenzoyl peroxide and 1.168 g (6.568 mmol) of N-bromosuccinimide. The resulting mixture was refluxed for 18 h, cooled, washed with sodium bisulfite solution and water, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was diluted with 10 mL of THF and 10 mL of 1N sodium hydroxide solution and the mixture was stirred at room temperature for 3 h. The reaction mixture was then acidified with 5% HCl and extracted with ether. The organics were dried over MgSO 4 , filtered and concentrated in vacuo. The residue was triturated with ether to provide 0.477 g (47%) of the product as a white solid. Electrospray Mass Spec: 350.1 (M+H)+.
EXAMPLE 322
3-Formyl-2- (4-methoxy-benzenesulfonyl)-octyl-amino!-benzoic acid methyl ester
To a solution of 1.0 g (2.865 mmol) of the product of Example 321 in 7.5 mL of DMF was added 0.143 g (3.582 mmol) of 60% sodium hydride followed by 0.74 mL (4.30 mmol) of n-octyl bromide. The reaction was stirred overnight at room temperature then diluted with ether, washed with water, dried over MgSO 4 , filtered and concentrated in vacuo. The resulting residue was chromatographed on silica gel eluting with EtOAc/hexanes (1:3) to provide 0.592 g (49%) of the product as a white solid. Electrospray Mass Spec: 462.1 (M+H)+.
EXAMPLE 323
3-Hydroxymethyl-2- (4-methoxy-benzenesulfonyl)-octyl-amino!-benzoic acid methyl ester
To a solution of 0.547 g (1.187 mmol) of the product of Example 322 in 10 mL of methanol and 3 mL of THF was added 0.045 g (1.187 mmol) of sodium borohydride. The reaction was stired for 2 h at room temperature and then concentrated in vacuo. The residue was diluted with ether and washed with 5% HCl and water, dried over MgSO 4 , filtered and concentrated in vacuo to provide 0.549 g (100%) as a colorless oil. Electrospray Mass Spec: 464.2 (M+H)+.
EXAMPLE 324
2- (4-Methoxy-benzenesulfonyl)-octyl-aminol-3-(4-methyl-piperazin-1-ylmethyl)-benzoic acid methyl ester
To a solution of 0.515 g (1.112 mmol) of the product of Example 323 in dichloromethane was added 0.438 g (1.668 mmol) of triphenylphosphine and 0.461 g (1.390 mmol) of carbon tetrabromide. The mixture was stirred for 1 h at room temperature and then concentrated in vacuo. The residue was filtered through a pad of silica gel eluting with EtOAc/hexanes (1:10) to provide the benzylic bromide.
To a solution of the bromide in 6.0 mL of DMF was added 0.136 mL (1.224 mmol) of N-methylpiperazine and 0.491 g (3.559 mmol) of potassium carbonate. The resulting mixture was stirred at room temperature overnight, diluted with ether, washed with water, dried over Na 2 SO 4 , filtered and concentrated in vacuo to provide 0.57 g (94%) of the benzylic amine-ester as a white solid. Electrospray Mass Spec: 546.2 (M+H)+.
EXAMPLE 325
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-octyl-amino! -3- (4-methyl-piperazin-1-ylmethyl)-benzamide
Following the procedure of Example 18, 0.507 g (0.930 mmol) of the product of Example 324 is converted into the corresponding carboxylate.
Following the procedure of Example 61 the carboxylate gives 0.343 g of the hydroxamic acid as a brown solid. Electrospray Mass Spec: 547.7 (M+H)+.
EXAMPLE 326
3-Formyl-2- (4-methoxy-benzenesulfonyl)-thiophen-3-ylmethyl-amino!-benzoic acid methyl ester
Following the procedure of Example 322, 1.0 g (2.865 mmol) of the product of Example 321 is reacted with 3-bromomethyl thiophene to give 1.10 g (86%) of the product as a white solid after chromatography on silica gel eluting with EtOAc/Hexanes (1:3). Electrospray Mass Spec: 446.1 (M+H)+.
EXAMPLE 327
2- (4-Methoxy-benzenesulfonyl)-thiophen-3-ylmethyl-amino!-3- (4-methyl-piperazin-1-ylmethyl)-benzoic acid
Following the procedure of Example 323, 1.06 g (2.387 mmol) of the product of Example 326 is converted into the corresponding alcohol.
Following the procedure of Example 324 the alcohol is converted into the corresponding benzylic amine-ester.
Following the procedure of Example 319 then gives 0.52 g of the carboxylic acid as a white solid. Electrospray Mass Spec: 516.2 (M+H)+.
EXAMPLE 328
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-thiophen-3-ylmethyl-amino!-3-(4-methyl-piperazin-1-ylmethyl)-benzamide
To a solution of 0.475 g (0.922 mmol) of the product of Example 327 in 8.0 mL of DMF was added 0.149 g (1.107 mmol) of HOBT and 0.235 g (1.227 mmol) of EDC. The reaction was then stirred for 1 h at room temperature and 0.28 mL (4.612 mmol) of a 50% solution of hydroxylamine in water was added. The reaction was stirred overnight and then concentrated in vacuo. The residue was diluted with EtOAc, washed with water and sodium bicarbonate solution, dried over Na 2 SO 4 , filtered and concenteeted in. The residue was dissolved in 5.0 mL of dichloromethane and 1.8 mL of a 1N solution of HCl in ether was added. After 1 h the reaction was diluted with ether and the resulting solid was filtered and dried in vacuo to give 0.242 g of the product as a white solid. Electrospray Mass Spec: 531.5 (M+H)+.
EXAMPLE 329
N-Hydroxy-2- (4-methoxyphenyl)sulfonyl! (phenylmethyl)-amino!-3- (4-methyl-1-piperazinyl)methyl!benzamide
Following the procedure of Example 322, 1.25 g (3.582 mmol) of the product of Example 321 reacts with benzyl bromide to give the N-benzyl sulfonamide.
Following the procedures of Examples 327, and 328, the sulfonamide gives 0.204 g of the hydroxamic acid as a white solid. Electrospray Mass Spec: 525.4 (M+H)+.
EXAMPLE 330
2-(4-Methoxy-benzenesulfonylamino)-3-methyl-benzoic acid tert-butylester
To a solution of 15.0 g (0.047 mol) of the product of Example 6 in 45 mL of toluene was added 50 mL of N,N-imethylformamide di-t-butyl acetal and the mixture was then heated to reflux for 18 h. The reaction was then cooled to room temperature and croatographed on silica gel eluting with EtOAc/Hexanes (1:3) to give 8.94 g (51%) of the product as a white solid. Electrospray Mass Spec: 378.1 (M+H)+.
EXAMPLE 331
2- (4-Methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid tert-butyl ester
Following the procedure of Example 187 2.5 g (6.631 mmol) of the product of Example 330 gives 2.59 g (100%) of the N-methyl sulfonamide as a white foam. Electospray Mass Spec: 392.4 (M+H)+.
EXAMPLE 332
(2S)-1-{3-tert-Butoxycarbonyl-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-benzyl}-pyrrolidine-2-carboxylic acid methyl ester
Following the procedure of Example 316, using L-proline methyl ester hydrochloride instead of pyrrolidine, 2.30 g (5.882 mmol) of the product of Example 331 gives 1.45 g (48%) of the diester as a white solid. Electrospray Mass Spec: 519.5 (M+H)+.
EXAMPLE 333
(2S)-1-{3-Carboxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-benzyl}-pyrrolidine-2-carboxylic acid methyl ester
To a solution of 1.39 g (2.678 mmol) of the product of Example 332 in 5.0 mL of dichloromethane was added 5.0 mL of trifluoroacetic acid. The reaction was stirred at room temperature for 2 h and then concentrated in vacuo. The residue was chromatographed on silica gel eluting with chlorofornmethanol (9:1) to give 1.24 g (100%) of the carboxylic acid as a white foam. Electrospray Mass Spec: 463.0 (M+H)+.
EXAMPLE 334
(2S)-1-{3-Hydroxycarbamoyl-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-benzyl}-pyrrolidine-2-carboxlic acid methyl ester
Following the procedure of Example 61 1.305 g (2.262 mmol) of the product of Example 333 gives 0.285 g of the hydroxamic acid as a tan solid. Electrospray Mass Spec: 478.1 (M+H)+.
EXAMPLE 335
3-Formyl-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-benzoic acid methyl ester
To a solution of 0.20 g (0.573 mmol) of the product of Example 321 in 2.5 mL of DMF was added 0.099 g (0.602 mmol) of 3-picolyl chloride hydrochloride and 0.249 g (1.805 mmol) of potassium carbonate. The reaction was stined for 18 h at room temperature and then the reaction was then diluted with water and extracted with ether. The combined organics were washed with water, dried over Na 2 SO 4 , filtered and concentrated in vacuo. The residue was triturated with ether to give 0.158 g (63%) of the product as tan crystals. Electrospray Mass Spec: 440.9 (M+H)+.
EXAMPLE 336
3-Hydroxymethyl-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-benzoic acid methyl ester
To a solution of 0.10 g (0.227 mmol) of the product of Example 335 in 5 mL of methanol and 2.0 mL of THF was added 8.6 mg of sodium borohydride. The reaction was stirred for 1 h at room temperature and then concentrated in vacuo. The residue was diluted with dichloromethane, washed with water, and the organics were then dried over Na 2 SO 4 , filtered and concentrated in vacuo. The resulting tan solid was washed with ether and dried in vacuo to give 0.086 g (86%) of the alcohol. Electrospray Mass Spec: 442.9 (M+H)+.
EXAMPLE 337
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-(tetrahydro-pyran-2-yloxymethyl)-benzoic acid methyl ester
To a solution of 0.500 g of the product of Example 336 in 15 mL of dichloromethane was added 0.21 mL (2.262 mmol) of dihydropyran and 0.030 g of toluenesulfonic acid monohydrate. The reaction was stirred at room temperate for 24 h and then diluted with dichloromethane. The organics were washed with 1N sodium hydroxide solution and water, dried over Na 2 SO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel eluting with EtOAc to give 0.436 g (73%) of the ThP-ether as a brown foam. Electrospray Mass Spec: 527.2 (M+H)+.
EXAMPLE 338
2- (4-Methoxyphenyl)sulfonyl!(3-pyridinylmethyl)amino!-3- (tetrahydro-2H-pyran-2-yl)oxy!methy!benzoic acid
Following the procedure of Example 190 0.376 g (0.715 mmol) of the product of Example 337 gives 0.370 g (100%) of the carboxylate salt as a brown foam. Electrospray Mass Spec: 511.1 (M-H)-.
EXAMPLE 339
N-Hydroxy-2- ((4-methoxy-benzenesulfonyl)- pyridin-3-ylmethyl-amino!-3-(tetrahydro-pyran-2-yloxymethyl)-benzamide
To a solution of 0.851 g (1.662 mmol) of the product of Example 338 in 10.0 mL of DMF was added 0.269 g (1.995 mmol) of HOBT (1-hydroxybenzotriazole) and 0.424 g (2.211 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodimide hydrochloride (EDC). The reaction was then stirred for 1 h at room temperature and 0.578 g (8.311 mmol) of hydroxylamine hydrochloride and 1.73 mL of triethylamine was added. The reaction was stired overnight and then concentrated in vacuo. The residue was diluted with ether, washed with water and sodium bicarbonate solution, dried over Na 2 SO 4 , filtered and concentrated in vacuo to provide 0.635 g (72%) of the hydroxamic acid as a tan foam. Electrosray Mass Spec: 528.1 (M+H)+.
EXAMPLE 340
N-Hydroxy-3-hydroxymethyl-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-benzamide
To a solution of 0.352 g (0.668 mmol) of the product of Example 339 in 6.5 mL of dichloromethane and 1.3 mL of methanol was added 1.3 mL of a 1M solution of HCl in ether. The reaction was stirred at room temperature for 5 h and the resulting precipitate was collcted by filtration, washed with ether and dried in vacuo to give 0.320 g (100%) of the alcohol as a white solid. Electrospray Mass Spec: 444.2 (M+H)+.
EXAMPLE 341
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-(2-hydroxy-ethoxy)-benzoic acid methyl ester
To a solution of 2.53 g (4.677 mmol) of the product of Example 38 in 20 mL of dichloromethane was added 5.0 mL of tifluoroacetic acid. The reaction was stirred at room tciaerpate for 3 h and then concentrated in vacuo. The residue was triturated with Ether/Hexanes (1:1) and the resulting white solid (2.063 g) was collected by filtration and dried in vacuo.
The carboxylic acid was then dissolved in 40 mL of dry THF cooled to 0° and 19.6 mL of a 1M solution of Borane/THF was added. The reaction was allowed to warm to room temperature and stirred for 18 h. The reaction was quenched with 10 mL of acetic acid-water (1:1), diluted with water and extracted with ether. The organics were died over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on sicca gel eluting with EtOAc)Hexanes (1:1) to provide 1.845 g of the alcohol as a white solid. Electrospray Mass Spec: 472.2 (M+H)+.
EXAMPLE 342
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-(2-hydroxy-ethoxy)-benzoic acid
To a solution of the product of 1.459 g (3.098 mmol) of Example 341 in 30 mL of THF/Methanol (1:1) was added 15.5 mL of 1N sodium hydroxide solution and the reaction mixture was then heated to reflux overnight. The reaction was then cooled to room temperature, acidified with 5% HCl solution and extracted with ether. The combined organics were dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chnoatographed on silica gel eluting with EtOAc/hexanes (2:1) to provide 1.22 g of the carboxy-alcohol as a white solid. Electrospray Mass Spec: 456.1 (M-)-.
EXAMPLE 343
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3- 2-(tert-butyl-dimethyl-silanyloxy)-ethoxy!-benzoic acid
To a solution of 1.22 g (2.67 mmol) of the product of Example 342 in 6.0 ml of DMF was added 0.966 g (6.407 mmol) of t-butyldimethylsilyl chloride and 0.908 g (0.013 mol) of imidazole. The reaction was stirred for 5 h at room temperature and then diluted with water and 1N sodium hydroxide solution and stirred for an additional hour. The reaction was then acidified to pH5 and extracted with ether. The organics were dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel eluting with EtOAc/bexanes (1:3) to provide 1.34 g (88%) of the carboxylic acid as a white solid. Electrospray Mass Spec: 570.0 (M+H)+.
EXAMPLE 344
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3- 2-(tert-butyl-dimethyl-silanyloxy)-ethoxy!-N-hydroxy-benzamide
Following the procedure of Example 328, 1.107 g (1.939 mmol) of the product of Example 343 gives 1.0 g (88%)of the hydroxamic acid as a white foam. Electrospray Mass Spec: 587.6 (M+H)+.
EXAMPLE 345
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-(2-hydroxy-ethoxy)-benzamide
To a solution of 0.957 g (1.633 mmol) of the product of Example 344 in 20 mL of acetonitrire was added 1.5 mL of 48% hydrofluoric acid. The reaction was stined at room temprature for 3 h and then diluted with dichloromethane and washed with water. The organics were dried over MgSO 4 , filtered and concentrated in vacuo to give 0.76 g (99%) of the hydroxamic acid as a white foam. Electrospray Mass Spec: 473.3 (M+H)+.
EXAMPLE 346
2-{5-Bromo-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methoxycarbonyl-benzyl}-malonic acid dimethyl ester
To a solution of 1.50 g (3.505 mmol) of the product of Example 202 in 65 mL of carbon tetrachloride was added 0.749 g (4.206 mmol) of N-bromosuccinimide and 0.06 g of dibenzoyl peroxide. The reaction was heated to reflux for 15 h, cooled and washed with water. The organics were dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel eluting with EtOAc/Hiexanes (1:3) to provide 1.46 g of the benzylic bromide.
To a solution of the benzylic bromide in 7.5 mL of DMF was added 0.39 mL (3.456 mmol) of dimethyl malonate followed by 0.171 g (3.168 mmol) of sodium methoxide. The reactioon was stirred at room temperature for 24 h then acidified with 10% HCl solution and extracted with ether. The organics were dried over MgSO 4 , filtered and concentraed in vacuo. The residue was chromatographed on silica gel eluting with EtOA/Hexanes (1:3) to provide 0.766 g (48%) of the triester as a colorless oil. Electrospray Mass Spec: 558.0 (M+H)+.
EXAMPLE 347
2-{5-Bromo-3-carboxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-benzyl}-malonic acid
Following the procedure of Example 342, 0.674 g (1.208 mmol) of the product of Example 45 gives 0.623 g (100%) of the triacid as a tan foam. Electrospray Mass Spec: 513.9 (M-H)-.
EXAMPLE 348
5-Bromo-3-(2-carboxy-ethyl)-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-benzoic acid
A solution of 0.542 g (1.050 mmol) of the product of Examnple 347 in 25 mL of pyridine was heated to reflux for 12 h and then cooled to room temperure. The reaction was diluted with water, acidified with 10% HCl solution and extracted with EtOAc. The combined organics were dried over MgSO 4 , filtered and concentrated in vacuo. The residue was triturated with ether to give 0.339 g of the diester as a tan solid. Electrospray Mass Spec: 470.0 (M-H)-.
EXAMPLE 349
5-Bromo-N-hydroxy-3- 2-(hydroxycarbamoyl)-ethyl!-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-benzamide
Following the procedure of Example 23 0.304 g (0.644 mmol) of the product of Example 348 gives 0.114 g (35%) of the bis-hydroxamic acid as a white solid. Electrospray Mass Spec: 504.0 (M+H)+.
EXAMPLE 350
N-Hydroxy-3- 2-(hydroxycarbamoyl)-ethyl!-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-benzamide
Following the procedures of Examples 346 to 349 the product of Example 188 gives the bis-hydroxamic acid as a white foam. Electrospray Mass Spec: 424.2 (M+H)+.
EXAMPLE 351
5-Biphenyl-4-ylethynyl-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid methyl ester
To a solution of 1.0 g (2.336 mmol) of the product of Example 202 in 7.5 mL of DMF was added 0.50 g (2.804 mmol) of ethynyl biphenyl, 0.033 g (0.047 mmol) of bis triphenylphosphine palladium(II) dichloride 4.4 mg of copper(I) iodide and 7.5 mL of triethylamine. The reaction was heated to 80° for 5 h and then diluted with ether. the organics were washed with water, 5% HCl solution and sodium bicarbonate solution, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel cluting with EtOAc/hexanes (1:3) to provide 0.777 g (63%) of the alkyne as a brown foam. Electrospray Mass Spec: 526.2 (M+H)+.
EXAMPLE 352
5-Biphenyl-4-ylethynyl-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid
Following the procedure of Example 18, 0.400 g (0.762 mmol) of the product of Example 351 gives 0.383 g (98%) of the carboxylic acid as a brown foam. Electrospray Mass Spec: 510.1 (M-H)-.
EXAMPLE 353
5-Biphenyl-4-ylethynyl-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzamide
Following the procedure of Example 23, 0.132 g (0.258 mmol) of the product of Example 352 gives 0. 107 g (79%) of the hydroxamic acid as a yellow solid. Electrospray Mass Spec: 527.1 (M+H)+.
EXAMPLE 354
5-(2-Biphenyl-4-yl-ethyl)-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid
To a solution of 0.20 g (0.391 mmol) of the product of Example 352 in 25 mL of methanol and 10 mL of ethyl acetate was added 0.050 g of 10% palladium on carbon. The mixture was hydrogenated in a Parr apparatus at 30 psi of hydrogen for 5 h, then filtered through Celite. The Celite pad was washed with 100 mL of methanol and 100 mL of ethyl acetate and the filtrate was concentrated in vacuo. The residue was trituratedwith ether to give 0.173 g (86%) of the carboxylic acid as a pale yellow solid. Electrospray Mass Spec: 514.2 (M-H)-.
EXAMPLE 355
5-(2-Biphenyl-4-yl-ethyl)-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzamide
Following the procedure of Example 23, 0.138 g (0.268 mmol) of the product of Example 354 gives 0.091 g (64%) of the hydroxamic acid as a yellow solid. Electrospray Mass Spec: 531.1 (M+H)+.
EXAMPLE 356
5-Dodec-1-ynyl-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid methyl ester
Following the procedure of Example 351, using 1-dodecyne instead of ethynyl biphenyl, 1.0 g (2.336 mmol) of the product of Example 202 gives 0.874 g (73%) of the alkyne as a brown oil. Electrospray Mass Spec: 514.4 (M+H)+.
EXAMPLE 357
5-Dodec-1-ynyl-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid
Following the procedure of Example 18, 0.808 g (1.575 mmol) of the product of Example 356 gives 0.731 g (93%) of the carboxylic acid as a pale yellow oil. Electrospray Mass Spec: 498.2 (M-H)-.
EXAMPLE 358
5-Dodec-1-ynyl-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzamide
Following the procedure of Example 23, 0.200 g (0.401 mmol) of the product of Example 357 gives 0.170 g (83%) of the hydroxamic acid as a colorless oil. Electrospray Mass Spec: 515.2 (M+H)+.
EXAMPLE 359
5-Dodecyl-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzoic acid
Following the procedure of Example 354, 0.217 g (0.435 mmol) of the product of Example 357 gives 0.214 g (98%) of the carboxylic acid as a pale white solid. Electspray Mass Spec: 502.3 (M-H)-.
EXAMPLE 360
5-Dodecyl-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-3-methyl-benzamide
Following the procedure of Example 23, 0.189 g (0.376 mmol) of the product of Example 359 gives 0.153 g (79%) of the hydroxamic acid as a brown oil. Electrospray Mass Spec: 519.2 (M+H)+.
EXAMPLE 361
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methoxymethyl-benzoic acid methyl ester
To a solution of 0.200 g (0.452 mmol) of the product of Example 336 in 5.0 mL of dry THF was added 0.022 g (0.543 mmol) of 60% sodium hydride followed by 0.028 mL of iodomethane. The reaction was stired at room temperature for 18 h and then diluted with ethyl acetate. The organics were washed with water and brine, dried over Na 2 SO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel eluting with EtOAc to provide 0.057 g (28%) of the methyl ether as ayellow solid. Electrospray Mass Spec: 457.3 (M+H)+.
EXAMPLE 362
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-
Following the procedure of Example 53, 0.275 g (0.603 mmol) of the product of Example 361 gives 0.267 g (100%) of the carboxylate salt as a yellow foam. Electspray Mass Spec: 443.1 (M+H)+.
EXAMPLE 363
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methoxymethyl-benzamide
Following the procedure of Example 328, 0.260 g (0.588 mmol) of the product of Example 362 gives 0.115 g of the hydroxamic acid as a tan solid. Electrospray Mass Spec: 456.3 (M-H)-.
EXAMPLE 364
3-Formyl-2-(4-methoxy-benzenesulfonylamino)-benzoic acid tert-butyl ester
Following the procedure of Example 321, 1.90 g (5.04 mmol) of the product of Example 330 gives 1.19 g (60%) of the aldehyde as a pale yellow solid. Electrospray Mass Spec: 392.2 (M+H)+.
EXAMPLE 365
3-Formyl-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethylamino!-benzoic acid tert-butyl ester
Following the procedure of Example 335, 1.106 g (2.829 mmol) of the product of Example 364 gives 1.282 (94%) of the N-picolyl sulfonamide as a brown oil. Electspray Mass Spec: 483.4 (M+H)+.
EXAMPLE 366
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-isophthalic acid mono-tert-butyl ester
To a solution of 0.417 g (0.865 mmol) of the product of Example 365 in 40 mL of water and 25 mL of THF was added 0.126 g (1.298 nmol) of sulfamic acid and 0.122 g (1.341 nmol) of sodium chlorite. The reaction was stirrd overnight at room temperature and then concentrated in vacuo. The residue was diluted with water and exte with chloroform. The organics were dried over Na 2 SO 4 , filtered and concentrated in vacuo. The residue was triturated with ether to give 0.080 g (77%) of the carboxylic acid as a pale yellow solid. Electrospray Mass Spec: 499.4 (M+H)+.
Example 367
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethylamino!-isophthalamic acid tert-butyl ester
Following the procedure of Example 328, 0.354 g (0.711 mmol) of the product of Example 366 gives 0.063 g (17%) of the hydroxamic acid as a brown foam. Electospray Mass Spec: 514.3 (M+H)+.
EXAMPLE 368
2- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-isophthalic acid monomethyl ester
Following the procedure of Example 366, 0.10 g (0.227 mmol) of the product of Example 335 gives 0.080 g (77%) of the carboxylic acid as a white solid. Electrospray Mass Spec: 457.3 (M+H)+.
EXAMPLE 369
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-isophthalamic acid methyl ester
Following the procedure of Exarmple 23, 0.600 g (1.316 mmol) of the product of Example 368 gives 0.48 g (77%) of the hydroxamic acid. The hydroxamate was dissolved in 10.0 mL of dichloromethane and 0.5 mL of methanol and 2.0 mL of a 1N solution of HCl in ether was added. After 1 h the resulting solid was filtered and dried in vacuo to give 0.358 g of the product as a tan solid. Electrospray Mass Spec: 472.2 (M+H)+.
EXAMPLE 370
3-Acetoxymethyl-5-bromo-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-benzoic acid methyl ester
To a solution of 1.00 g (2.336 mmol) of the product of Example 202 in 50 mL of carbon tetrachloride was added 0.457 g (2.57 mmol) of N-bromosuccinimide the reaction was heated to reflux under a sunlamp for 1 h, cooled and washed with water. The organics were dried over MgSO 4 , filtered and concentrated in vacuo. The residue was dissolved in 15 mL of DMF and 0.958 g (0.012 mmol) of sodium acetate was added. The reaction was heated to 80° for 4 h, cooled to room temperature and diluted with ether. The organics were washed with water, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel eluting with EtOAc/hexanes (1:3) to provide 0.408 g (36%) of the acetate as a colorless oil. Electrospray Mass Spec: 487.8 (M+H)+.
EXAMPLE 371
5-Bromo-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-isophthalic acid monomethyl ester
To a solution of 0.272 g (0.826 mmol) of the product of Example 370 in 2.0 mL of THF/MeOH (1:1) was added 0.87 mL of 1N sodium hydroxide solution and the reaction was stir for 3 h at room temperature. The reaction was then extracted with ether. The combined organics were dried over MgSO 4 , filtered and concentrated in vacuo. The residue was triturated with ether to give 0.241 g of the alcohol as a white solid.
The alcohol was then dissolved in 1.5 mL of DMF and 0.366 g (0.973 mmol) of pyridinium dichromate was added and the reaction was stirred overnight. The reaction mixture was then diluted with ether, washed with water, dried over MgSO 4 , filtered and concentrated in vacuo. The residue was dissolved in 17 mL of THF and 28 mL of water and 0.091 g (1.005 mmol) of sodium chlorite and 0.094 g (0.973 mmol) of sulfamic acid was added. The reaction was stirred overnight at room temperature, concentrated in vacuo, diluted with water and extraced with chloroform. The orgamics were dried over MgSO 4 , filtered and concentrated in vacuo. The residue was triturated with ether to give 0.282 g of the carboxylic acid as a white solid. Electrospray Mass Spec: 456.0 (M-H)-.
EXAMPLE 372
2- (4-Methoxy-benzenesulfonyl)-methyl-amino!-isophthalic acidmonomethyl ester
Following the procedure of Example 370, 0.50 g (1.168 mmol) of the product of Example 188 gives 0.314 g (66%) of the acetate. Following the procedure of Example 371 0.287 g (0.705 mmol) of the acetate gives 0.152 g of the carboxylic acid as a white solid. Electrospray Mass Spec: 377.9 (M-H)-.
EXAMPLE 373
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-methyl-amino!-isophthalamic acid methyl ester
Following the procedure of Example 23, 0.126 g (0.332 mmol) of the product of Example 372 gives 0.116 g (89%) of the hydroxamic acid as a white solid. Electrospray Mass Spec: 394.8 (M+H)+.
EXAMPLE 374
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-isophthalamic acid
To a solution of 0.235 g (0.458 mnmol) of the product of Example 367 dissolved in 5 mL of dichlo ethane was added 2 mL of trifluoroacetic acid. The reaction was stirred at room tcnperature for 2 h and then concentrated in vacuo. The residue was triturated with ether and the resulting solid was collected by filtration and dried in vacuo to give 0.178 (65%) of the hydroxamic acid as a tan solid. Electrospray Mass Spec: 456.4 (M-H)-.
EXAMPLE 375
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-2-ylmethyl-amino!-3-methyl-benzamide
Following the procedure of Example 45, 0.750 g (2.239 mmol) of the product of Example 3 was alkylated with 2-picolyl chloride hydrochloride to give 0.916 g (96%) of the N-picolyl sulfonamide.
Following the procedure of Example 53 the ester was then hydrolyzed to provide the corresponding carboxylic acid.
Following the procedure of Example 369 the acid was converted into the hydroxamic acid to give 0.180 g of the pyridinium salt as a brown foam. Electrospray Mass Spec: 428.1 (M+H)+.
EXAMPLE 376
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-4-ylmethyl-amino!-3-methyl-benzamide
Following the procedure of Example 45, 0.750 g (2.239 mmol) of the product of Example 3 was alkylated with 4-picolyl chloride hydrochloride to give 0.897 g (94%) of the N-picolyl sulfonamide.
Following the procedure of Example 53 the ester was then hydrolyzed to provide the corresponding carboxylic acid.
Following the procedure of Example 369 the acid was converted into the hydroxamic acid to give 0.180 g of the pyridinium salt as a brown foam. Electrospray Mass Spec: 428.2 (M+H)+.
EXAMPLE 377
2- (4-Diethylaminomethyl-benzyl)-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-methyl-benzamide
Following the procedure of Example 9, 1.50 g (4.478 mmol) of the product of Example 3 was alkylated with 4-carboethoxybenzyl bromide to give 2.00 g (93%) of the benzylated sulfonamide as a tan solid. Electrospray Mass Spec: 484.2 (M+H)+.
This ester was dissolved in 9.0 mL of MeOH/THF (1:1) and 4.3 mL of 1.0N sodium hydroxide solution was added. The reaction was stired for 3 h at room temperature, acidified with 5% HCl solution and extracted with ethyl acetate. The combined organics were dried over MgSO 4 , filtered and concentrated in vacuo to give the carroxylic acid as a white solid which was washed with ether and dried. Electrospray Mass Spec: 468.5 (M-H)-.
The acid was then reduced with borane-THF as in Example 341, to provide the alcohol as a white solid. Electrospray Mass Spec: 456.2 (M+H)+.
The alcohol was converted into the corresponding diethylamine, according to the procedure in Example 324, isolated as a white solid. Electrospray Mass Spec: 511.5 (M+H)+.
Hydrolysis of the benzoate ester according to the procedure of Example 319, followed by conversion to the hydroxamic acid and salt formation according to the procedure of Example 369 gives 0.105 g of the hydroxamate as a white solid. Electrospray Mass Spec: 512.1 (M+H)+.
EXAMPLE 378
2- (4-Dimethyl-aminomethyl-benzyl)-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-methyl-benzamide
Following the procedures of Example 377, 1.50 g (4.478 mmol) of the product of Example 3 was converted into the dimethylamine-hydroxamate, isolated as a white foam. Electrospray Mass Spec: 483.9 (M+H)+.
EXAMPLE 379
2- (4-Methoxy-benzenesulfonyl) prop-2-ynyl-amino!-3-methyl-benzoic acid methyl ester
Following the procedure of Example 9, 1.50 g (4.478 mmol) of the product of Example 3 was alkylated with propargyl bromide to give 1.33 g (79%) of the propargyl sulfonamide as a white solid. Electrospray Mass Spec: 374.3 (M+H)+.
EXAMPLE 380
2- (4-Diethylamino-but-2-ynyl)-(4-methoxy-benzenesulfonyl)-amino!-3-methyl-benzoic acid methyl ester
To a solution of 1.27 g (3.61 mmol) of of the product of Example 379 in 11 mL of dioxane and 1.3 mL of acetic acid was added 0.293 g of paraformaldehyde, 0.75 mL of diethylamine and 13 mg of cuprous chloride. The reaction was stire at room temperture for 15 minutes and then heated to reflux for 1.5 h, after which the reaction color had changed from green to brown. The reaction was cooled and then extted with 10% HCl solution. The acid wash was then basified with 1N sodium hydroxide solution and extracted with ether. The combined organics were dried over Na 2 SO 4 , filtered and concentrated in vacuo to give 1.56 g (100%) of the propargylic amine as a brown oil. Electrospray Mass Spec: 459.5 (M+H)+.
EXAMPLE 381
2- (4-Diethylamino-but-2-ynyl)-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-methyl-benzamide
Following the procedure of Example 319, 1.50 g (3.275 mmol) of the product of Example 380 was hydrolyzed to give 0.86 g (59%) of the carboxylic acid as a tan foam. Electrospray Mass Spec: 443.4 (M-H)-.
Following the procedure of Example 328, 0.649 g (1.462 mmol) of the carboxylic acid gives 0.228 g of the hydroxamic acid-amine salt as a tan solid. Electrospray Mass Spec: 460.1 (M+H)+.
EXAMPLE 382
N-Hydroxy-2-{(4-methoxy-benzenesulfonyl)- 4-(4-methyl-piperazin-1-yl)-benzyl!-amino}-3-methyl-benzamide
Following the procedure of Example 9, 1.50 g (4.478 mmol) of the product of Example 3 was alkylated with 4-bromobenzyl bromnide to give 2.16 g (96%) of the benzylated sulfonamide as a pale yellow solid. Electrospray Mass Spec: 504.0 (M+H)+.
To a solution of 2.04 g (4.048 mrol) of the aryl bromide in 60 mL of toluene was added 0.99mL (8.91 mmol) of N-methylpiperazine, 0.856 g (8.91 mmol) of sodium t-butoxide, 0.148 g (0.162 nunol) of tris-(dibenzylideneacetone)dipalladium and 0.301 g (0.486 mmol) of (R)-(+)-2,2'-bis(diphenylphosphino-1'-binaphthyl (BINAP). The resulting mixture was heated to 80° for 3 h then cooled to room temperature. The reaction was diluted with ether and filtered through Celite. The filtrate was concentrated in vacuo and the residue was chromatographed on silica gel eluting with ethyl acetate to give 1.3 g of the aryl pipera.ine.
Following the procedure of Example 319 the aryl piperazine-ester was hydrolyzed to give 0.837 g (66%) of the carboxylic acid as a brown foam. Electrospray Mass Spec: 508.6 (M-H)-.
Following the procedure of Example 328 the carboxylic acid was converted into 0.432 g of the hydroxamic acid-amine salt, isolated as a pale yellow solid. Electrospray Mass Spec: 525.1 (M+H)+.
EXAMPLE 383
4- (2-Hydroxycarbamoyl-6-methyl-phenyl)-(4-methoxy-benzenesulfonyl)-amino!-butyric acid ethyl ester
Following the procedure of Example 45, 0.750 g (1.989 mmol) of the product of Example 330 was rted with ethyl bromobutyrate to give 0.96 g (98%) of the alkylated sulfonamide as a colorless oil. Electrospray Mass Spec: 492.4 (M+H)+.
To a solution of 0.828 g (1.686 mmol) of the t-butyl ester in 5 mL of dichloromethane was added 5.0 mL of trifluoroacetic acid. The reaction was stirred at room temperature for 2 h and then concentrated in vacuo. The residue was triturated with ether/hexanes (1:1) and the resulting white solid carboxylic acid (0.653 g) was collected by filtration and dried in vacuo. Electrospray Mass Spec: 434.2 (M-H)-.
Following the procedure of Example 23, 0.603 g (1.386 mmol) of the carboxylic acid gives 0.234 g (38%) of the hydroxamic acid as a white foam. Electrospray Mass Spec: 451.4 (M+H)+.
EXAMPLE 384
5- (2-Hydroxycarbamoyl-6-methyl-phenyl)-(4-methoxy-benzenesulfonyl)-amino!-pentanoic acid ethyl ester
Following the procedure of Example 45, 0.750 g (1.989 mmol) of the product of Example 330 was reacted with ethyl bromovalerate to give 0.93 g (93%) of the alkylated sulfonamide as a white solid. Electrospray Mass Spec: 506.4 (M+H)+.
To a solution of 0.813 g (1.610 mmol) of the t-butyl ester in 5 mL of dichloromethane was added 5.0 mL of trifluoroacetic acid. The reaction was stirred at room temperature for 2 h and then concentrated in vacuo. The residue was triturated with ether/hexanes (1:1) and the resulting white solid carboxylic acid (0.693 g) was colkcted by filtration and dried in vacuo. Electrospray Mass Spec: 448.1 (M-H)-.
Following the procedure of Example 23, 0.631 g (1.405 mmol) of the carboxylic acid gives 0.219 g (34%) of the hydroxamic acid as a brown glass. Electrospray Mass Spec: 465.4 (M+H)+.
EXAMPLE 385
(2-Hydroxycarbamoyl-6-methyl-phenyl)-(4-methoxy-benzenesulfonyl)-amino!-acetic acid benzyl ester
Following the procedure of Example 9, 1.50 g (3.979 mmol) of the product of Example 330 was reacted with benzyl 2-bromoacetate to give 2.03 g (97%) of the alkylated sulfonamide as a colorless oil. Electrospray Mass Spec: 526.3 (M+H)+.
To a solution of 1.00 g (1.905 mmol) of the t-butyl ester in 5 mL of dichloromethane was added 5.0 mL of trirluoroacetic acid. The reaction was stirred at room temperature for 1 h and then concentrated in vacuo to give 0.893 g (100%) of the carboxylic acid as a white foam. Electrospray Mass Spec: 468.2 (M-H)-.
Following the procedure of Example 23, 0.802 g (1.71 mmol) of the carboxylic acid gives 0.675 g (82%) of the hydroxamic acid as a white foam. Electrospray Mass Spec: 485.3 (M+H)+.
EXAMPLE 386
N-Hydroxy-2- (4-methoxyphenyl)sulfonyl! 2-oxo-2- (2pyridinylmethyl)-amino!ethyl!amino!-3-methlylbenamide
Following the procedure of Example 9, 4.0 g (0.011 mol) of the product of Example 330 was reacted with benzyl 2-bromoacetate to give 5.57 g (100%) of the alkyad sulfonamide as a colorless oil. Electrospray Mass Spec: 526.3 (M+H)+.
To a solution of 5.50 g (0.010 mol) of the benzyl ester in 150 mL of ethanol was added 3.30 g (0.052 mol) of ammonium formate and 0.550 g of 10% palladium on carbon. The reaction was stired at room temperature for 18 h and then filtered through celite. The filtrate was concentrated in vacuo, diluted with ethyl acetate, washed with water, dried over MgSO 4 , filtered and concentrated. The residue was chromatographed on silica gel eluting with EtOAc/hexanes (1:1) to give the carboxylic acid as a white foam. Electrospray Mass Spec: 436.2 (M+H)+.
To a solution of 1.00 g (2.299 mmol) of the carboxylic acid in 10 mL of dichloromethane was added 0.36 mL of DMF followed by 2.3 mL of a 2M solution of oxalyl chloride in dichloromethane. The reaction was stirred at room temperature for 1 h and then poured into a 0° C. solution of 0.47 mL (4.598 mmol) of 2-aminomethylpyridine and 0.96 mL of triethylamine in 10 mL of dichloromethane. The reaction was stirred overnight and then poured into water and extrccted with ether. The organics were then washed with water, dried over Na 2 SO 4 , filtered and concentrated in vacuo. The residue was choomatogwaphed on silica gel eluting with ethyl acetate to give 1.094 g (91%) of the amide as a white foam. Electrospray Mass Spec: 526.4 (M+H)+.
Next, HCl gas was bubbled through a solution of 0.985 g (1.876 mmol) of the amide dissolved in 20 mL of dichloromethane for 10 minutes. The reaction was stoppered and stirred for an additional 1 h and then diluted with 50 mL of ether and let sit overnight. The resulting white solid carboxylic acid was collected by filtration and dried in vacuo. Electrospray Mass Spec: 468.1 (M-H)-.
Following the procedure of Example 328, 0.850 g (1.682 mmol) of the carboxylic acid gives 0.693 g of the hydroxamic acid-amine salt as a tan solid. Electrospray Mass Spec: 485.3 (M+H)+.
EXAMPLE 387
N-Hydroxy-2-{(4-methoxy-benzenesulfonyl)- 2-(4-methyl-piperazin-1-yl)-2-oxo-ethyl!-amino}-3-methyl-benzamide
Following the procedure of Example 9, 4.0 g (0.011 mol) of the product of Example 330 was reacted with benzyl 2-bromoacetate to give 5.57 g (100%) of the alkylated sulfonamide as a colorless oil. Electrospray Mass Spec: 526.3 (M+H)+.
To a solution of 5.50 g (0.010 mol) of the benzyl ester in 15.0 mL of ethanol was added 3.30 g (0.052 mol) of amnonium formate and 0.550 g of 10% palladium on carbon. The reaction was stirred at room temperature for 18 h and then filtered through celite. The filtrate was concentrated in vacuo, diluted with ethyl acetate, washed with water, dried over MgSO 4 , filtered and concentrated. The residue was chromatographed on silica gel eluting with EtOAc/hexanes (1:1) to give the carboxylic acid as a white foam. Electrospray Mass Spec: 436.2 (M+H)+.
To a solution of 1.00 g (2.299 mmol) of the carboxylic acid in 10 mL of dichloromethane was added 0.36 mL of DMF followed by 2.3 mL of a 2M solution of oxalyl chloride in dichlcwo thane. The reaction was steeed at room terpeanre for 1 h and then poured into a 0° solution of 1.3 mL (0.011 mmol) of N-methylpiperazine in 10 mL of dichloromethane. The reaction was stirred overnight and then poured into water and extracted with ether. The organics were then washed with water, dried over Na 2 SO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel eluting with ethyl acetate to give 1.19 g (100%) of the amide as a colorless oil. Electrospray Mass Spec: 518.4 (M+H)+.
Next, HCl gas was bubbled through a solution of 1.10 g (2.128 mmol) of the amide dissolved in 25 mL of dichloromethane for 10 minutes. The reaction was stoppered and stirred for an additional 1 h and then diluted with 50 mL of ether and let sit overnight. The resulting white solid cafroxylic acid was collected by filtration and dried in vacuo. Electrospray Mass Spec: 459.8 (M-H)-.
Following the procedure of Example 328, 0.927 g (1.863 mmol) of the carboxylic acid gives 0.350 g of the hydroxamic acid-amine salt as a white solid. Electrospray Mass Spec: 477.3 (M+H)+.
EXAMPLE 388
N-Hydroxy-2- (2-hydroxy-ethyl)-(4-methoxy-benzenesulfonyl)-amino!-3-methyl-benzamide
Following the procedure of Example 9, 2.0 g (5.97 mmol) of the product of Example 3 was reacd with t-butyl bromoacetate to give 2.38 g (89%) of the alkylated sulfonamide as a colorless oil. Electrospray Mass Spec: 449.9 (M+H)+.
To a solution of 2.20 g (4.90 mmol) of the t-butyl ester in 10 mL of dichloromethane was added 5.0 mL of trifluoroacetic acid. The reaction was stirred at room temperature for 2 h and then concentrated in vacuo. The residue was triturated with ether and the resulting white solid carboxylic acid (1.85 g) was collected by filtration and dried in vacuo. Electrospray Mass Spec: 392.0 (M-H)-.
The acid (1.75 g, 4.45 mmol) was then reduced with borane-THF as in Example 341, to provide 1.21 g of the alcohol as a white solid. Electrospray Mass Spec: 379.9 (M+H)+.
Following the procedure of Example 337, 0.812 g (2.142 mmol) of the alcohol then gives 0.910 g (92%) of the terahydropyranyl ether. This ether-ester is then hydrolyzed following the procedure of Example 19 to give 0.634 g (72%) of the carboxylic acid as a brown glass. Electrospray Mass Spec: 372.2 (M+Na)+.
Following the procedure of Example 328, 0.592 g (1.318 nmuol) of the ether-carboxylate then gives 0.105 g of the hydroxy-hydroxamic acid as a tan solid. Electrospray Mass Spec: 381.1 (M+H)+.
EXAMPLE 389
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-5-dimethyl-amino-N-hydroxy-3-methyl-benzamide
To a solution of 0.83 g (1.649 mmol) of the product of Example 11 in 25.0 mL of toluene was added 0.639 (3.627 mmol) of tris(dimethyl-amino)borane, 0.349 (3.627 mmol) of sodium t-butoxide, 0.060 g (0.066 mmol) of tris-(dibenzylideneacetone)-dipalladium and 0.123 (0.198 mmol) of BINAP. The resulting mixture was heated to 80° for 3 h then cooled to room temperature. The reaction was diluted with ether and filtered through Celite. The filtrate was concentrated in vacuo and the residue was chromatographed on silica gel eluting with EtOAc/Hexanes (1:3) to give 0.342 g (44%) of the N,N-dimethyl aniline-ester.
Following the procedure of Example 53 0.356 g (0.761 mmol) of the N,N-dimethyl aniline-ester is hydrolyzed to give 0.170 g (50%) of the carboxylic acid as a white solid. Electrospray Mass Spec: 453.1 (M-H)-.
Following the procedure of Example 369, 0.225 g (0.496 mmol) of the carboxylc acid gives 0.159 g (69%) of the hydroxamic acid-aniline salt as a pale yellow foam. Electrospray Mass Spec: 469.9 (M+H)+.
EXAMPLE 390
2- Benzyl-(4-methoxy-benzenesulfonyl)-amino!-3-dimethyl-amino-N-hydroxy-benzamide
To a solution of 0.100 g (0.219 mmol) of the product of Example 168 in 10 mL of ethanol was added 0.247 g (1.096 mmol) of SnCl 2 dihydrate and the reaction mixture was then heated to reflux for 3 h. After cooling to room temperature the reaction was concentreed in vacuo and then diluted with ether. The organics were washed with 1N sodium hydroxide solution and water, dried over Na 2 SO 4 , filtered and concentred in vacuo. The residue was triturated with ether to give 0.060 g of the aniline as a white solid. Electrospray Mass Spec: 426.9 (M+H)+.
To a solution of 0.455 g (1.068 mmol) of the aniline in 10 mL of DMF was added 1.44 g (0.011 mol) of potassium carbonate and 0.66 mL of iodomethane and the reaction was heated to 80° for 18 h. The reaction was then allowed to cool to room temperature and diluted with ether. The organics were washed with water, dried over Na 2 SO 4 , filtered and concentrated in vacuo. The residue was chromatographed on silica gel eluting with EtOAc/hexanes (1:3) to give 0.44 g (91%) of the N,N-dimethyl aniline-ester as a pink oil. Electrospray Mass Spec: 454.9 (M+H)+.
Following the procedure of Example 53, 0.388 g (0.855 mmnol) of the N,N-dimethyl aniline-ester gives 0.314 g (82%) of the N,N-dimethyl aniline-arboxylate as a white foam. Electrospray Mass Spec: 439.0 (M-H)-.
Following the procedure of Example 369, 0.251 g (0.563 mmol) of the carboxylate gives 0.226 g (88%) of the hydroxamic acid as a pink foam. Electrospray Mass Spec: 455.9 (M+H)+.
EXAMPLE 391
4-(2-Piperidin-1-yl-ethoxy)-benzyl chloride
To a stirred solution of 4-hydroxy benzaldehyde (12.2 gm, 0.1 mol) and K2CO3 (25 gm, excess) in N,N-dimethlformamide (250 ml) was added 1-(2-chloroethyl)piperidine monohydrochloride (20.0 gm, 1.08 mol). The reaction mixture was heated to 80° C. for 24 hrs and cooled to room temperature. The reaction mixture was quenched with ice cold water and extracted with chloroform. The organics were washed with water, dried over anhydrous MgSO 4 , filtered and concentrated in vacuo. The residue was dissolved in methanol and sodium borohydride (10 gms, excess) was slowly added at 0° C. The reaction mixture was stirred at room temperature for 2 h and then quenched with water. The alcohol was extracte with chloroform, the organics were washed well with water, dried over Na 2 SO 4 , filtered and concentrated in vacuo.
The crude alcohol thus obtained was dissolved in THF (200 ml) and HCl gas was passed through for 30 minutes at 0° C. To the suspension of hydrochloride thus obtained, thionyl chloride (30 ml, excess) was slowly added. The reaction mixture was refluxed for thirty minutes and cooled to room temperature. The reaction mixture was then concentrated to dryness and triturated with anhydrous ether. The precipitated solid was filtered and dried under vacuum at room temperature to give 25 g (86%) of the product as a white solid. m.p. 145-148° C. Electrospray Mass Spec: 256 (M+H).
EXAMPLE 392
4-(2-N,N-Diethyl-ethoxy)-benzyl chloride
To a stirred solution of 4-hydroxy benzaldehyde (12.2 gm, 0.1 mol) and K 2 CO 3 (25 gm, excess) in N,N-diethlformamide (250 ml) was added 2-diethyl-aminoethyl chloride monohydrochloride (20.0 gm, 1.2 mol). The reaction mixture was heated at 80° C. for 24 hrs and cooled to room temperature. The reaction mixture was quenched with ice cold water and extracted with chloroform. The organics were washed with water, dried over anhydrous MgSO 4 , filtered and concentrated in vacuo. The residue was dissolved in methanol and sodium borohydride (10 gms, excess) was slowly added at 0° C. The reaction mixture was stirred at room temperature for 2 h and then quenched with water. The alcohol was extracted with chloroform, washed well with water, dried, filtered and concentrated in vacuo.
The crude alcohol thus obtined was dissolved in ThF (200 ml) and HCl gas was passed through for 30 minutes at 0° C. To the suspension of hydrochloride thus obtained, thionyl chloride (30 ml, excess) was slowly added. The reaction mixture was refluxed for thirty minutes and cooled to room temperature. The reaction mixture was then concentrated to dryness and triturated with anhydrous ether. The precipitated solid was filtered and dried under vacuum at room temperature to give 18 g (65%) of the product as a white solid, m.p. 76-79° C. Electrospray Mass Spec: 244 (M+H).
EXAMPLE 393
N-Hydroxy-2- (4-methoxyphenyl)sulfonyl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methyl!amino!-3-methylbenzamide
Following the procedure of Example 45, 1.00 g (2.985 mmol) of the product of Example 3 reacts with 0.952 g (3.284 mmol) of the product of Example 391 to give 0.965 g (58%) of the piperidine-ester as a colorless oil. Electrospray Mass Spec: 553.5 (M+H)+.
Following the procedure of Example 319, 0.889 g (1.611 mmol) of the ester gives 0.872 g of the carboxylic acid as a white foam. Electrospray Mass Spec: 539.2 (M+H)+.
Following the procedure for Example 328, 0.814 g (1.513 mmol) of the carboxylic acid gives 0.179 g of the hydroxamate-amine salt as a white solid. Electrospray Mass Spec: 554.5 (M+H)+.
EXAMPLE 394
2- 4-(2-Diethylamino-ethoxy)-benzyl!-(4-methoxy-benzenesulfonyl)-amino!-N-hydroxy-3-methyl-benzamide
Following the procedure of Example 45, 1.00 g (2.653 mmol) of the product of Example 30 rtacts with 0.811 g (2.918 mmol) of the product of Example 392 to give 0.575 g (37%) of the pipeidine-ester as a tan foam. Electrospray Mass Spec: 583.1 (M+H)+.
Following the procedure of Exanple 374, 0.539 g (0.926 mmol) of the ester gives 0.369 g of the carboxylic acid as a white solid. Electrospray Mass Spec: 525.2 (M-H)-.
Following the procedure for Example 369, 0.328 g (0.513 mmol) of the caxboxylic acid gives 0.194 g of the hydroxamate-amine salt as a white solid. Electrospray Mass Spec: 542.3 (M+H)+.
EXAMPLE 395
5-Bromo-N-hydroxy-2-{(4-methoxy-benzenesulfonyl)- 4-(2piperidin-1-yl-ethoxy)-benzyl!-amino}-3-methyl-benzamide
Following the procedures for Example 393, 1.00 g (2.415 nmol) of the product of Example 202 gives 0.470 g of the hydroxamate-amine salt as a pale yellow solid. Electrosray Mass Spec: 632.2 (M+H)+.
EXAMPLE 396
N-Hydroxy-2- (4-methoxyphenyl)sulfonyl! 4- 2-(1-piperidinyl)ethyl!amino!carbonyl!phenyl!methyl!amino!-3-methylbenzambide
Following the procedure of Example 9, 1.00 g (2.653 mmol) of the product of Example 330 reacts with 0.851 g (3.714 numol) of para-carbomethoxy benzyl bromide to give 1.30 g (94%) of the benzylated sulfonamide-ester as a white foan. Electrospray Mass Spec: 526.4 (M+H)+.
To a solution of 0.1.249 g (2.379 mmol) of the ester in 24.0 mL of THF/MeOH (1:1) was added 12 mL of 1N sodium hydroxide solution and the reaction was stirred for 3 h at room temperature. The reaction was then acidified and ex=aWd with ethyl acetate. The combined organics were dried over MgSO 4 , filtered and concentrated in vacuo to give 0.1.08 g (89%) of the carboxylic acid as a white foam. Electrospray Mass Spec: 512.3 (M+H)+.
To a solution of 1.01 g (1.977 mmol) of the carboxylic acid in 10 mL of dichloromethane was added 0.306 mL of DMF followed by 2.0 mL of a 2M solution of oxalyl chloride in dichloromethane. The reaction was stirred at room temperatre for 1 h and then poured into a 0° C. solution of 0.56 mL (3.95 mmol) of aminoethyl piperidine and 0.825 mL of triethylamine in 7 mL of dichloromethane. The reaction was stired overnight and then poured into water and extracted with ether. The organics were then washed with water, dried over Na 2 SO 4 , filtered and concentrated in vacuo to give 1.23 g (100(%) of the amide as a white foarm Electrospray Mass Spec: 622.6 (M+H)+.
Next, HCl gas was bubbled through a solution of 1.167 g (1.879 mmol) of the amide dissolved in 20 mL of dichloromethane for 10 minutes. The reaction was stoppered and stirred for an additional 1 h and then diluted with 50 mL of ether and let sit overnight. The resulting white solid carboxylic acid was collected by filtration and dried in vacuo. Electrospray Mass Spec: 566.6 (M+H)+.
Following the procedure of Example 328, 1.023 g (1.704 nunol) of the carboxylic acid gives 0.177 g of the hydroxamate-amine salt as a white solid. Electrospray Mass Spec: 581.0 (M+H)+.
EXAMPLE 397
4- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-biphenyl-3-carboxylic acid hydroxyamide hydrochloride salt
Following the procedure of Example 241 the product of Example 89 reacts with phenylboronic acid to give the corresponding biaryl-sulfonamide-ester. The ester is subsequendy hydrolyzed to the carboxylic acid following the procedure of Example 319 and then converted into the hydroxamic acid hydrochloride salt following the method of Example. 369. Electrospray Mass Spec: 504.5 (M+H)+.
EXAMPLE 398
N-Hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-5-thiophen-3-yl-benzamide hydrochloride salt
Following the procedure of Example 241 the product of Example 89 reacts with thiophene-3-boronic acid to give the corresponding biaryl-sulfonamide-ester. The ester is subsequently hydrolyzed to the carboxylic acid following the procedure of Example 319 and then converted into the hydroxamic acid hydrochloride salt following the method of Example 369. Electrospray Mass Spec: 508.1 (M-H)-
EXAMPLE 399
4"-Methoxy-4- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl- 1,1';4',1"!terphenyl-3-carboxylic acid hydroxyamide hydrochloride salt
Following the procedure of Example 241 the product of Example 89 reacts with 4-(4'-methoxyphenyl)phenylboronic acid to give the corresponding biaryl-sulfonamide-ester. The ester is subsequently hydrolyzed to the carboxylic acid following the procedure of Example 319 and then converted into the hydroxamic acid hydrochloride salt following the method of Example 369. Electrospray Mass Spec: 609.9 (M+H)+.
EXAMPLE 400
4- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-3'-nitro-biphenyl-3-carboxylic acid hydroxyamide hydrochloride salt
Following the procedure of Example 241 the product of Example 89 reacts with 3-nitrobenzeneboronic acid to give the corresponding biaryl-sulfonamide-ester. The ester is subsequently hydrolyzed to the carboxylic acid following the procedure of Example 319 and then converted into the hydroxamic acid hydrochloride salt following the method of Example 369. Electrospray Mass Spec: 549.1 (M+H)+
EXAMPLE 401
4'-Methoxy-4- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-biphenyl-3-carboxylic acid hydroxyamide hydrochloride salt
Following the procedure of Example 241 the product of Example 89 reacts with 4 methoxybenzeneboronic acid to give the corresponding biaryl-sulfonamnide-ester. The ester is subsequently hydrolyzed to the carboxylic acid following the procedure of Example 319 and then converted into the hydroxamic acid hydrochloride salt following the method of Example 369. Electrospray Mass Spec: 534.1 (M+H)+
EXAMPLE 402
5-Benzo b!thiophen-2-yl-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzamide hydrochloride salt
Following the procedure of Example 241 the product of Example 89 reacts with benzo b!thiophene-2-boronic acid to give the corresponding biaryl-sulfonamide-ester. The ester is subsequently hydrolyzed to the carboxylic acid following the procedure of Example 319 and then converted into the hydroxamic acid hydrochloride salt following the method of Example 369. Electrospray Mass Spec: 560.1 (M+H)+
EXAMPLE 403
5-Benzo b!furaphen-2-yl-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl benzamide hydrochloride salt
Following the procedure of Example 241 the product of Example 89 reacts with benzo b!furan-2-boronic acid to give the corresponding biaryl-sulfonamide-ester. The ester is subsequently hydrolyzed to the carboxylic acid following the procedure of Example 319 and then converted into the hydroxamic acid hydrochloride salt following the method of Example 369. Electrospray Mass Spec: 544.3 (M+H)+
Example 404
4- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-4'-trifluoromethoxy-biphenyl-3-carboxylic acid hydroxyamide hydrochloride salt
Following the procedure of Example 241 the product of Example 89 reacts with 4-trifluoromethoxybenzeneboronic acid to give the corresponding biaryl-sulfonamide-ester. The ester is subsequently hydrolyzed to the carboxylic acid following the procedure of Example 319 and then converted into the hydroxamic acid hydrochloride salt following the method of Example 369. Electrospray Mass Spec: 588.1 (M+H)+
EXAMPLE 405
5-Benzo 1,3!dioxol-5-yl-N-hydroxy-2- (4-methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzamide hydrochloride salt
Following the procedure of Example 241 the product of Example 89 reacts with 3,4-methylenedioxybenzeneboronic acid to give the corresponding biaryl-sulfonamide/ester. The ester is subsequently hydrolyzed to the carboxylic acid following the procedure of Example 319 and then converted into the hydroxamic acid hydrochloride salt following the method of Example 369. Electrospray Mass Spec: 548.1 (M+H)+
EXAMPLEI 406
4- (4-Methoxy-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-5-methyl-3'-trifluoromethyl-biphenyl-3-carboxylic acid hydroxyamide hydrochloride salt
Following the procedure of Example 241 the product of Example 89 reacts with 3-trifluoromethylbenzeneboronic acid to give the corresponding biaryl-sulfonanide-cter. The ester is subsequently hydrolyzed to the carboxylic acid following the procedure of Example 319 and then converted into the hydroxamic acid hydrochloride salt following the method of Example 369. Electrospray Mass Spec: 572.0 (M+H)+.
EXAMPLE 407
2- (4-Chloro-benzyl)-(5-pyridin-2-yl-thiophene-2-sulfonyl)-amino!-N-hydroxy-3-methyl-benzamide
A mixture of Wang resin (Wang, S. J. Am. Chem. Soc. 1973, 95, 1328-1333) (Advanced ChemTech 200-400 mesh, 1% crosslinked; loading: 0.92 mmol/g; 15.0 g, 0.011 mol), LiCl (1.4 g, 0.033 mol) and DMF (150 mL) was magnetically stired for 40 min. Collidine (4.0 g, 0.033 mol) was added and the mixture was cooled (0-5° C.) with an ice bath. Methanesulfonyl chloride (3.8 g, 0.033 mol) was added over 5 min. After 10 min. the cooling bath was removed and stirring was continued for 68 h. The mixture was filtaed and the resin was washed with DMF (250 mL), 30% H 2 O/DMF ((2×300 mL), DMF (2×250 mL), EtOH (3×250 mL), CH 2 Cl 2 (3×300 mL), and hexane (2×250 mL). The resin was dried over P 2 O 5 in vacuo to give 14.3 g; 13 C NMR (CDCl 3 ) δ 46.22 (CH 2 Cl); IR (KBr) cm -1 : 2900, 1600, 1520, 1485, 1450.
A mixture of chloWang resin (1.13 mmol/g, 1 g), NaI (169 mg, 1.13 mmol), Cs 2 CO 3 (1.11 g, 3.39 mmol) and N-hydroxyphthalimide (922 mg, 5.65 mmol) in DMF was heated at 50° C. for 16 h. After filtration, the resin was washed with DMF/H 2 O (3:2, 4×25 mL), DMF/H 2 O (9:1, 4×25 mL), DMF (2×25 mL), dichloromethane (3×25 mL) and MEOH (2×20 mL). The resin was then dried under vacum to give the product resin (1.1 g, 96%). N% theory 1.38%, found 1.09%.
Phthalimido hydroxylamine resin (10 g) was treated with a mixture of THF/EtOH/NH 2 NH 2 (80 mL/80 mL/26 mL) for 18 h at room temperature. The mixture was filtered and the resin was washed with MeOH (200 mL), DMF (200 mL), and the process was repeated. The resin was then washed with MeOH (200 mL) and dichloromethane (2×150 mL). Finally the resin was dried under vacuum.
A cold (-5° C., ice-salt bath) solution of 2-amino-3methylbenzoic acid (1.51 g, 10 mmol) and pentafluorophenol (2 g, 11 mmol) in dry DMF (2 mL) was treated with a solution of DCC (2.27 g, 11 mmol) in EtOAc (20 mL). The reaction mixture was stored at 0° C. overnight. The precipitate was removed by filtration and washed with EtOAc (˜10 mL). The washings were combined with the filtrate and washed with 5% aqueous NaHCO 3 (2×15 mL), H 2 O (15 mL) and dried (Na 2 SO,). The solvent was removed to give the product (3.2 g, 100%) as a solid.
To a suspension of hydroxylamine on Wang resin (3.05 g, 1.13 mmol/g) in DMF was added a solution of pentafluorophenyl 2-amino-3-methylbenzoate (4.37 g, 13.8 mmol) followed by 4-dimethylarinopyridine (2.1 g, 17.2 mmol). The resultant mixture was shaken at room tempertue for 40 h. The resin was filtered and washed with DMF (4×100 ml), dichloromethane (3×80 mL), MeOH (2×80 mL), and dichloromethane (4×80 mL). Finally the resin was dried under vacum to give product resin (3.51 g, 100%).
To a suspension of 2-amino-3-methylbenzoic acid hydroxyamide on Wang resin (3.51 g, 0.98 mmol/g) in dichloromethane (20 mL) was added pyridine (2.78 mL, 34.4 mmol). After 5 min, a solution of 5-(pyridin-2-yl)thiophen-2-yl-sulfonyl chloride (4.46 g, 17.2 mmol) in dichloromethane (15 mL) was added to the reaction mixture. The resultant suspension was shaken at room temperature for 24 h. The resin was filtered and washed with DMF (4×40 mL), dichloromethane (3×40 mL), MeOH (2×40 mL) and dichlncthane (4×40 mL), and dried under vacum to give 4.25 g (97%) of product resin.
To confirm the completion of the reaction, a sample of resin (100 mg) was suspended in TFA/dichloromethane (1:1,2 mL) and allowed to sit for 1 h. The resin was filtered and washed with dichloromethane (2×1.5 mL). The combined filtrates were evaporated to dryness to give 24.7 mg of product, (5-pyridin-2-yl-thiophene-2-sulfonyl)-amino!-N-hydroxy-3-methyl-benzamide on Wang Resin. Mass Spec: expected 389.0504, found 389.9.
To a suspension of (5-pyridin-2-yl-thiophene-2-sulfonyl)-amino!-N-hydroxy-3-methyl-benzamide on Wang resin (100 mg, 0.84 mmol/g) in a solution of 4chlorobenzyl alcohol (0.485 mmol) in ThF (1 mL) was added a solution of triphenylphosphine (0.485 mmol) and diethyl azodicarboxylate (0.485 mmol) in THF (1.24 mL). The resultant mixture was shaken for 4 h at room temperature. The resin was filtered, washed with THF (4×3 mL) and dichloromethane (4×3 mL), and dried under vacuum. The resin was suspended in trifluoroacetic acid/ dichloromethane (1:1, 2 mL) and allowed to sit for 1 h. The resin was filtered and washed with dichloromethane (2×1.5 mL). The combined filtrates were evaporated to dryness, and the crude product was purified on a solid phase exton cartridge (reverse phase) to give 16.7 mg of product, 2- (4-chloro-benzyl)-(5-pyridin-2-yl-thiophene-2-sulfonyl)-amino!-N-hydroxy-3-methyl-benzamide. mass Spec: Spec: expected 513.0584, found 513.8.
EXAMPLE 408
2- (3,4-Dimethyl-benzyl)-(5-pyridin-2-yl-thiophene-2-sulfonyl)-amino!-N-hydroxy-3-methyl-benzamide
To a suspension of (5-pyridin-2-yl-thiophene-2-sulfonyl)-amino!-N-hydroxy-3-methyl-benzamide on Wang resin, the product of Example 407 (100 mg, 0.84 mmol/g), in a solution of 3,4 dimethylbenzyl alcohol (0.485 mmol) in THF (1 mL) was added a solution of triphenylphosphine (0.485 mmol) and diethyl azodicarboxylate (0.485 mmol) in THF (1.24 mL). The resultant mixture was shaken for 4 h at room temperature. The resin was filtered, washed with THF (4×3 mL) and dichloromethane (4×3 mL), and dried under vacuum. The resin was suspended in trifluoroacetic acid/ dichloromethane (1:1, 2 mL) and allowed to sit for 1 h. The resin was filtered and washed with DCM (2×1.5 mL). The combined filtrates were evaporated to dryness, and the crude product was purified on a solid phase extraction cartridge (reverse phase) to give 18.1 mg of product Mass Spec: expected 507.1286, found 507.9.
EXAMPLE 409
2- (4-Bromo-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-3-methyl-benzoic acid methyl ester
Following the procedure of Example 1, methyl-3-methyl anthranilate reacts with p-bromobenzenesulfonyl chloride to provide the aryl sulfonamide as a white powder. Electrospray Mass Spec: 475 (M+H)+.
EXAMPLE 410
N-Hydroxy-3-methyl-2- pyridin-3-ylmethyl-(4 '-trifluoromethyl-biphenyl-4-sulfonyl)-amino!-benzamide
Following the procedure of Example 241, the product of Example 409 is converted into the biaryl sulfonamide-ester. Hydrolysis of the ester according to the procedure of Example 190 gives the corresponding carboxylic acid. The carboxylic acid is then converted into the hydroxamic acid, isolated as an off-white powder, according to the procedure of Example 68. Electrospray Mass Spec: 542.1 (M+H)+.
EXAMPLE 411
2- (2',4'-Dimethoxy-biphenyl-4-sulfonyl)-pyridin-3-ylmethyl-amino!-N-hydroxy-3-methyl-benzamide
Following the procedure of Example 241, the product of Example 409 is converted into the biaryl sulfonamide-ester. Hydrolysis of the ester according to the procedure of Example 190 gives the corresponding carboxylic acid. The carboxylic acid is teen converted into the hydroxamic acid, isolated as an off-white powder, according to the procedure of Example 68. Electrospray Mass Spec: 534.0 (M+H)+.
EXAMPLE 412
N-Hydroxy-3-methyl-2- pyridin-3-ylmethyl-(4-thiophen-2-yl-benzenesulfonyl)-amino!-benzamide
Following the procedure of Example 241, the product of Example 409 is converted into the bivyl sulfonamide-ester. Hydrolysis of the ester according to the procedure of Example 190 gives the corresponding carboxylic acid. The carboxylic acid is then converted ihto the hydroxamic acid, isolated as an off-white powder, according to the procedure of Example 68. Electrospray Mass Spec: 480.3 (M+H)+.
EXAMPLE 413
2- (4-Ethynyl-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-N-hydroxy-3-methyl-benzamide
Following the procedure of Examnple 78 the product of Example 409 is converted into the alkynl-aryl sulfonamide-ester. Hydrolysis of the ester according to the procedure of Example 190 gives the corresponding carboxylic acid. The carboxylic acid is then converted into the hydroxamic acid, isolated as an off-white powder, according to the procedure of Example 68. Electrospray Mass Spec: 422.3 (M+H)+.
EXAMPLE 414
2- (4-Benzo b!thiophen-2-yl-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-N-hydroxy-3-methyl-benzamide
Following the procedure of Example 241, the product of Example 409 is converted into the biaryl sulfonamide-ester. Hydrolysis of the ester according to the procedure of Example 190 gives the corresponding carboxylic acid. The carboxylic acid is then converted into the hydroxamic acid, isolated as an off-white powder, according to the procedure of Example 68. Electrospray Mass Spec: 530.0 (M+H)+.
EXAMPLE 415
2- (4-Benzo 1,3!dioxol-5-yl-benzenesulfonyl)-pyridin-3-ylmethyl-amino!-N-hydroxy-3-methyl-benzamide
Following the procedure of Example 241, the product of Example 409 is converted into the biaryl sulfonamide-ester. Hydrolysis of the ester according to the procedure of Example 190 gives the corresponding carboxylic acid. The carboxylic acid is then converted into the hydroxamic acid, isolated as an off-white powder, according to the procedure of Example 68. Electrospray Mass Spec: 518 (M+H)+.
EXAMPLE 416
3-Methyl-2- 4-(pyidin-4-yloxy)-benzensulfonylamino!-N-hydroxy-benzoic acid methyl ester
Following the procedure of Example 1, the product of Example 3 reacts with 4- (pyrid-4-yl)oxy!benzenesulfonyl chloride hydrochloride to provide the NH-sulfonamide as a white powder. Electrospray Mass Spec: 399 (M+H)+.
EXAMPLE 417
3-Methyl-2- 4-(pyridin-4-yloxy)-benzensulfonylamino!-N-hydroxy-benzamide
Following the procedure of Example 9, the NH-sulfonamide product of Example 416 reacs with iodomethane to provide the N-methyl sulfonamide-ester.
Hydrolysis of the ester according to the procedure of Example 190 gives the corresponding carboxylic acid. The carboxylic acid is then converted into the hydroxamic acid, isolated as a white powder, according to the procedure of Example 68. Electropray Mass Spec: 414 (M+H)+.
Pharmacology
Procedures for Measuring MMP-1, MMP-9, and MMP-13 Inhibition
These assays are based on the cleavage of a thiopeptide substrates such as Ac-Pro-Leu-Gly(2-mercapto-4-methyl-pentanoyl)-Leu-Gly-OEt by the matrix metalloproteinases MMP-1, MMP-13 (collagenases) or MMP-9 (gelatinase), which results in the release of a substrate product that reacts coloimetrically with DTNB (5,5'-dithiobis(2-nitro-benzoic acid)). The enzyme activity is measured by the rate of the color increase. The thiopeptide substrate is made up fresh as a 20 mM stock in 100% DMSO and the DTNB is dissolved in 100% DMSO as a 100 mM stock and stored in the dark at room temperature. Both the substrate and DTNB are diluted together to 1 mM with substrate buffer (50 mM HEPES pH 7.5, 5 mM CaCl 2 ) before use. The stock of enzyme is diluted with assay buffer (50 mM HEPES, pH 7.5, 5 mM CaCl 2 , 0.02% Brij) to the desired final concentration. The assay buffer, enzyme, vehicle or inhibitor, and DThB/substrate are added in this order to a 96 well plate (total reaction volume of 200 μl) and the increase in color is monitored spectiophotometrically for 5 minutes at 405 nm on a plate reader and the increase in color over time is plotted as a linear line.
Alternatively, a fluorescent peptide substrate is used. In this assay, the peptide substrate contains a fluorescent group and a quenching group. Upon cleavage of the substrate by an MMP, the fluorescence that is generated is quantitated on the fluorescence plate reader. The assay is run in HCBC assay buffer (50 mM HEPES, pH 7.0, 5 mM Ca +2 , 0.02% Brij, 0.5% Cysteine), with human recombinant MMP-1, MMP-9, or MMP-13. The substrate is dissolved in methanol and stored frozen in 1 mM aliquots. For the assay, substrate and enzymes are diluted in HCBC buffer to the desired concentrations. Compounds are added to the 96 well plate containing enzyme and the reaction is started by the addition of substrate. The reaction is read (excitation 340 nm, emission 444 nm) for 10 min. and the increase in fluorescence over time is plotted as a linear line.
For either the thiopeptide or fluorescent peptide assays, the slope of the line is calculated and represents the reaction rate. The linearity of the reaction rate is confirmed (r 2 >0.85). The mean (x±sem) of the control rate is calculated and compared for statistical significance (p<0.05) with drug-treated rates using Dunnett's multiple comparison test. Dose-response relationships can be generated using multiple doses of drug and IC 50 values with 95% CI are estimated using linear regression.
In vivo MMP Inhibition
A 2 cm piece of dialysis tubing (molecular weight cut-off 12-14,000, 10 mm flat width) containing matrix metalloproteinase enzyme (stromelysin, coflagenase or gelatnase in 0.5 mL of buffer) is implanted either ip or sc (in the back) of a rat (Sprague-Dawley, 150-200 g) or mouse (CD-1, 2514 50 g) under anesthesia. Drugs are administered PO, IP, SC or IV through a canula in the jugular vein. Drugs are administered in a dose volume of 0.1 to 0.25 mL/animal. Contents of the dialysis tubing is collected and enzyme activity assayed.
Enzyme reaction rates for each dialysis tube are calculated. Tubes from at least 3 different animals are used to calculate the meani sem. Statistical significance (p<0.05) of vehicle-treated animals versus drug-treated animals is determined by analysis of variance. (Agents and Actions 21: 331, 1987).
Procedure for Measuring TACE Inhibition
Using 96-well black microtiter plates, each well receives a solution composed of 10 μL TACE (Immunex, final concentration 1 μg/mL), 70 μL Tris buffer, pH 7.4 containing 10% glycerol (final concentration 10 mM), and 10 μL of test compound solution in DMSO (final concentration 1 μM, DMSO concentration <1%) and incubated for 10 minutes at room temperature. The reaction is initiated by addition of a fluorescent peptidyl substrate (final concentration 100 μM) to each well and then shaking on a shaker for 5 sec.
The reaction is read (excitation 340 nm, emission 420 nm) for 10 min. and the increase in fluorescence over time is plotted as a linear line. The slope of the line is calculated and represents the reaction rate.
The linearity of the reaction rate is confined (r 2 >0.85). The mean (x±sem) of the control rate is calculated and compared for statistical significance (p<0.05) with drug-treated rates using Dunnert's multiple comparison test. Dose-response relationships can be generate using multiple doses of drug and IC 50 values with 95% CI are estimated using linear regression.
Results of the above in-vitro and in-vivo matrix metalloproteinase inhibition and TACE inhibition phamalogical assays are given in Table I below.
TABLE I______________________________________Inhibition of MMP and TACEEx-amp- in-vivole MMP-1.sup.1 MMP-9.sup.1 MMP-13.sup.1 MMP.sup.2 TACE.sup.1______________________________________23 639 650 555 >100024 398 31 100025 32%(100), ip >100026 884 346 982 >100027 1573 440 717 >100028 115 23 50 46029 553 353 728 100034 281 28 69 31.6(100), ip >100054 24 3 455 670 29 216 >100056 >1000 57 138 >100057 >500 12 33 100058 244 5 36 68259 242 8 34 >100060 152 7 15 23261 34 33 46(20), po 289 59(50), po68 82 21 15 23969 153 874 1370 >100072 >1000 144 137 37774 >1000 554 959 42977 13180 109 21 18 13483 34 3285 663 >100088 132 15 11 5091 24 20 55(100), po94 1000 276 209 >1000101 267 23 138 422102 314 29 162115 >1000 11 20 173116 201 13 14 271117 114 10 10 28.3(100), ip 154118 248 345 229 >1000119 223 27 14 252120 238 18 39 310125 >1000 27 134 300130 213 4 13 76131 212 54 48 80138 258 77 57 215145 55 7 3 158150 213 4 13 76151 212 54 48 80156 >1000 104 134158 >1000 11 62165 286 350166 203 >300167 42 178170 347 12 39 176174 323 16 71 50%175 90 7 4 57179 680 40 53 64%186 37 13 1.4 61191 1239 10 67 210194 306 12 154197 711 5 6 32%201 104 11 27 1000207 1117 2.0 2.5 375212 415 5.2 11 314214 423 6.4 19 232219 290 6.7 5.8 548224 957 11 14 715227 193 3.1 4.1 446230 20 2.4 1.9 47%(1)233 32 2.3 1.8 450240 86 3.5 1.6 548243 528 6.6 3.1 66246 106 6.0 3.6 56249 231 2.8 6.0 100252 652 15 10 346255 48 7.1 3.2 65258 169 8.0 7.0 110261 247 1.3 2.8 54264 159 3.7 6.4 77267 59 3.0 13 136272 66 0.5 6.0 311277 56 4.0 4.0 34282 1050 5.0 113 44%(1)285 312 6.0 9.8 61292 184 8.0 29 7%(1)297 297 9.0 14 58%(1)301 211 6.9 8.7 1484302 291 24 173303 2782 64 104 218%(1)304 4100 305 25%(1)308 10%(1) 45%(1) 36%(1) 285309 608 5 14 174310 4800 21 101 154311 781 10 43 157313 180 1.4 6.3 26314 954 8.4 13 27320 2188 46 150 142325 15%(1) 49%(1) 60%(1) 1640325 20 2.4 1.9 47%(1)328 326 4.9 13 263329 319 6.1 23 173339 216 5.2 5.7 564340 522 11 30 110344 1173 69 320 529345 1158 31 134 523349 396 8 9 32350 450 5 21 373353 23%(1) 61 141 780355 701 28 20 288358 25%(10) 101 107 1054360 14%(10) 525 1260 1405363 449 20 54 137367 597 12 13 2700369 207 6.4 3.8 38373 1280 26 59 539374 56%(10) 36%(1) 17%(1) 29%(1)375 329 7.1 18 356376 391 8.4 18 645377 123 4.7 15 258378 213 2.9 11 243381 470 11 19 218382 142 6.5 20 146383 34%(1) 87%(1) 48%(1) 45%(1)384 48%(1) 52%(1) 61%(1) 55%(1)385 25%(1) 65%(1) 66%(1) 56%(1)386 21%(1) 16%(.1) 11%(.1) 46%(1)387 2715 96 307 38%(1)388 66%(10) 47%(1) 39%(1) 35%(1)389 63 2 39 633390 19%(1) 64 531 39%(1)393 176 6.9 56 277394 96 2.3 8.8 215395 35 2.3 3.1 108396 184 6.3 35 363397 195 3.0 3.7 64398 85 2.0 3.7 56399 2197 45 41 25%(1)400 295 6.0 4.9 231401 176 1.4 2.8 146402 543 2.6 8.5 639404 1800 5.9 9.5 54%(1)405 176 4.1 5.8 151406 542 1.1 1.6 294407 1690 199 35408 3450 731 148410 47%(10) 28%(1) 40%(.1) 2%(1)411 32%(10) 39%(1) 44%(1) 9%(1)412 69%(10) 44%(1) 42%(.1) 3%(1)413 529 55 75 43%(1)414 29%(10) 68%(1) 38 6%(1)415 37%(10) 43%(1) 26 9%(1)417 3245 6.8 3.7______________________________________ .sup.1 IC.sub.50 nM or % inhibition at 1 μM concentration .sup.2 % inhibition vs. MMP9(dose, mg/kg), ip = intraperitoneal, po = ora
Cartilage Degradation in the Rat
Twenty mg slices of cartilage are obtained from the knee of freshly slaughtered cattle. Discs of cellulose sponge, 6 mm in diameter, are cut and a 2 mm hole put in the center of the sponge. 100 μl of a sterile suspension containing 1 mg of heat-killed Myco bu m tuberculosis is applied to the sponge. After air-drying overnight, the sponges are autoclaved and a cartilage slice is placed in the hole cut in the sponge disc. Under sterile conditions, the cartilage-sponge disc is placed subcutaneously in the back of an anesthetized rat (Lewis strain, 200 to 250 g). The incision is closed with staples and the rat allowed to recover from anesthesia. Approximately 5 days after sponge implantation, osmotic minipumps (Alza Corp., Palo Alto, Calif.), containing either investigational conpound or vehicle were implanted intraperitoneally in the anesthetized rat under sterile conditions After 19 days, the rats are euthanieed by asphyxiation with CO 2 and the granulomas containing the implanted sponge excised from the surrounding tissue.
The weight of the piece of cartilage recovered from the sponge was recorded and the collagen content of the cartilage was determined. The mean of the cartilage weights and collagen content was determined for the vehicle and drug-treated groups. The inhibition of cartilage weight and collagen content loss produced by the compounds compared with vehicle-tated rats was determined. Statistical significance (p<0.05) of vehicle-treated animals versus drug-treated animals was determined by analysis of variance.
Results:
______________________________________ Average Daily % Inhibition of % Inhibition of Dose Cartilage Weight Cartilage CollagenTreatment (mg/kg) Loss Loss______________________________________E ample 83 50 44.6 51.2*E ample 313 50 45.5 28.0*______________________________________ * = p < 0.05 vs Vehicletreated rats
Reference Bishop J., Greenham A K., Lewis E J. A novel in vivo model for the study of cartilage degradation. J. Pharmacol. Toxicol. Methods, 30:19-25, 1993.
Pharmaceutical Composition
Compounds of this invention may be administered neat or with a pharmaceutical carrier to a patient in need thereof. The pharmaceutical carrier may be solid or liquid.
Applicable solid carriers can include one or more substances which may also act as flavoring agents, lubricants, solubilizers, suspending agents, fillers, glidants, compression aids, binders or tablet-sintegrating agents or an encapsulating material. In powders, the carrier is a finely divided solid which is in admixture with the finely divided active ingredient. In tablets, the active ingredient is mixed with a carrier having the necessary compression properties in suitable proportions and compacted in the shape and size desired. The powders and tablets preferably contain up to 99% of the active ingredient. Suitable solid carers include, for example, calcium phosphate, magnesium stearate, talc, sugars, lactose, dextrin, starch, gelatin, cellulose, methyl cellulose, sodium carboxymethyl cellulose, polyvinylpyrrolidine, low melting waxes and ion exchange resins.
Liquid carriers may be used in preparing solutions, suspensions, emulsions, syrups and elixirs. The active ingredient of this invention can be dissolved or suspended in a phrmaeutically acceptable liquid carrier such as water, an organic solvent, a mixture of both or pharmaceutically acceptable oils or fat. The liquid carrier can contain other suitable pharmaceutical additives such a solubilizers, emulsifiers, buffers, preservatives, sweeteners, flavoring agents, suspending agents, thickening agents, colors, viscosity regulators, stabilizers or osmo-regulators. Suitable examples of liquid carriers for oral and parenteral administration include water (particularly containing additives as above, e.g., cellulose derivatives, preferable sodium carboxymethyl cellulose solution), alcohols (including monohydric alcohols and polyhydric alcohols, e.g., glycols) and their derivatives, and oils (e.g., fractionated coconut oil and arachis oil). For parenteral administration the carfier can also be an oily ester such as ethyl oleate and isopropyl myristate. Sterile liquid carriers are used in sterile liquid form compositions for parenteral administration.
Liquid pharmaceutical compositions which are sterile solutions or suspensions can be utilized by, for example, intramuscular, intrpeitoneal or subcutaneous injection. Sterile solutions can also be administered intravenously. Oral administration may be either liquid or solid composition form.
The compounds of this invention may be adninistered rectally in the form of a conventional suppository. For administration by intranasal or intrabronchial inhalation or insufflation, the compounds of this invention may be formulated into an aqueous or partially aqueous solution, which can then be utilized in the form of an aerosol. The compounds of this invention may also be administered transdermally through the use of a tansdrmal patch containing the active compound and a carrier that is inert to the active compound, is non-toxic to the skin, and allows delivery of the agent for systemic absorption into the blood stream via the skin. The carrier may take any number of forms such as crems and ointments, pastes, gels, and occlusive devices. The crews and ointments may be viscous liquid or semi-solid emulsions of either the oil in water or water in oil type. Pastes comprised of absorptive powders dispersed in petroleum or hydrophilic petoleum containing the active ingredient may also be suitable. A variety of occlusive devices may be used to release the active ingredient into the blood stream such as a semipermeable membrane covering a reservoir containing the active ingredient with or without a carrier, or a matrix containing the active ingredient. Other occlusive devices are known in the literature.
The dosage to be used in the treatment of a specific patient suffering from a disease or condition in which MMPs and TACE are involved must be subjectively deterrd by the attending physician. The variables involved include the severity of the dysfunction, and the size, age, and response pattern of the patient. Treatment will generally be initiated with small dosages less than the optimum dose of the compound. Thereafter the dosage is increased until the optimum effect under the circumstances is reached. Precise dosages for oral, parenteral, nasal, or intrabronchial administration will be determined by the admiddering physician based on experience with the individual subject treated and standard medical principles.
Preferably the phartaceutical composition is in unit dosage form, e.g., as tablets or capsules. In such form, the composition is sub-divided in unit dose containing appropriate quantities of the active ingredient; the unit dosage form can be packaged compositions, for example packed powders, vials, ampoules, prefilled syringes or sachets containing liquids. The unit dosage form can be, for example, a capsule or tablet itself, or it can be the appropriate number of any such compositions in package form. | The present invention relates to the discovery of novel, low molecular weight, non-peptide inhibitors of matrix metalloproteinases (e.g. gelatinases, stromelysins and collagenases) and TNF-α converting enzyme (TACE, tumor necrosis factor-α converting enzyme) which are useful for the treatment of diseases in which these enzymes are implicated such as arthritis, tumor growth and metastasis, angiogenesis, tissue ulceration, abnormal wound healing, periodontal disease, bone disease, proteinuria, aneurysmal aortic disease, degenerative cartilage loss following traumatic joint injury, demyelinating diseases of the nervous system, graft rejection, cachexia, anorexia, inflammation, fever, insulin resistance, septic shock, congestive heart failure, inflammatory disease of the central nervous system, inflammatory bowel disease, HIV infection, age related macular degeneration, diabetic retinopathy, proliferative vitreoretinopathy, retinopathy of prematurity, ocular inflammation, keratoconus, Sjogren's syndrome, myopia, ocular tumors, ocular angiogenesis/neovascularization.
The TACE and MMP inhibiting ortho-sulfonamido aryl hydroxamic acids of the present invention are represented by the formula ##STR1## where the hydroxamic acid moiety and the sulfonamido moiety are bonded to adjacent carbons on group A. | 2 |
BACKGROUND OF THE INVENTION
To increase the productivity of machines which process yarns, filaments and other elongated elements, it is possible, inter alia, to increase the yarn or filament travel speed of such machines. In the exemplary case of a spinning machine, this means an increase of the machine rotary speed. However, there are practical limits to the extent to which productivity can be boosted by boosting the rotary speed of the machine drive and accordingly the spindle speed. In particular, after a certain point, further increases in spindle rotary speed lead to yarn or filament breakages occurring at an unacceptably high frequency. Unacceptably high breakage frequencies are disadvantageous because, on the one hand, they decrease operating efficiency and, on the other hand, because they evidently have a negative effect upon the quality of the finished yarn, filament or other elongated element. For example, in the case of yarn being wound onto a cop, if the yarn breaks the partially filled cop is not replaced; instead, the broken yarn is tied, either manually or by means of an automatic knotter. Accordingly, the number of yarn breakages per unit time is directly reflected in the number of knots in the yarn per unit length and thus constitutes one elementary measure of quality.
Breakage of yarns, filaments or other elongated members in a function not only of the characteristics of the yarns of filaments, and of the processing operations to which they are subjected, including climatic conditions. Additionally, and in the exemplary case of a ring-traveller-type spinning machine, the yarn breakage frequency is dependent upon the mechanical and in general the physical characteristics of the machine and its operation, including those of the yarn-winding spindle and of the drawing mechanism. A further important cause of yarn breakage is high-frequency variation of the tensile load borne by the yarn (or other elongated element) attributable for the most part to imperfect mounting or geometry of the rotary and other components of the spinning mechanism.
Because of the many factors which contribute to breakages of yarns, filaments and other elongated elements, it is at best extremely difficult to determine the dominating cause or causes of high breakage frequency. For this reason, automatic intervention into the breakage-producing factors, which would be highly desirable, is scarcely possible. In this connection, it should be additionally noted that the causes which dominate may change with time, so that after a while different causes, for example temporary climatic conditions, may become the dominating causes of yarn breakage.
To the foregoing it should be added that in the past persons skilled in the art were limited to merely providing for the generation of optical or acoustic signals in response to yarn breakages.
SUMMARY OF THE INVENTION
It is a general object of the invention to create a situation making possible the determination of at least those factors which are primarily responsible for the yarn breakage frequency, with the aim of reducing or eliminating the effect of those factors, so as to achieve optimal-cost production conditions or, in the case of increasing demands upon quality and operation as well as mechanical-physical structural conditions, to utilize the possibilities within the framework of the invention in a manner characterized by optimum cost and suitability for manufacture.
These objects, and others which will become more understandable from the description, below, of preferred embodiments, can be met, according to one advantageous concept of the invention, by employing a measuring device which directly or indirectly monitors the travel of yarns, filaments, or other such elongated elements, in a processing machine in general, or in a spinning machine in particular. According to the invention, the measuring device advantageously forms part of a control or regulating circuit (e.g., a servo loop), and more particularly forms part of the device in such servo loop which is operative for generating a signal indicative of the actual yarn breakage frequency. In particular, the measuring device can furnish a number of signals proportional to the number of yarn breakages occurring per preselectable unit time, with these signals being applied to means for registering the actual-value signal, with the breakage-frequency indicating signal thusly generated being used, after the elapse of the time interval in question, for comparison against a reference breakage frequency, and with the discrepancy between the actual-value and desired-value breakage frequency signals being utilized as an error-correcting or compensating signal, which is applied to a compensating device or the like operative for varying the speed of the machine drive in a sense reducing the discrepancy. With such an arrangement, it becomes possible by introducing a certain preselected yarn breakage number, relative to a unit time, to so control the yarn travel speed of the machine that the preselected acceptable yarn breakage frequency is not markedly exceeded or fallen below. This means that the yarn travel speed of the individual machines, in dependence upon the respective product whose quality is to be optimized and in conjunction with the secondary requirements, can be properly selected automatically and then automatically maintained at an 6 optimum value, so as to guarantee an optimum production cost for the yarns, filaments, or other elongated elements.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of the working part of a ring spinning machine;
FIG. 2 is a perspective detail view of the ring and ring traveller of the spinning machine;
FIG. 3 is a top view of a portion of the ring and of the ring traveller, and of circuitry associated therewith;
FIG. 4 is a schematic circuit diagram of a regulating arrangement; and
FIGS. 5-7 depict circuit details of additional regulating arrangements.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As can be seen from the Figures, the yarn (spun or unspun), fiber yarn, filament yarn or filamentary structure 1 travels from a roving bobbin 3, passes through the so-called slubbing guide 4 and reaches the drawing mechanism 5, from which it emerges as fine yarn, then travels through the yarn-guide eyelet 7, and is wound onto the spool 11 by means of the ring-and-traveller arrangement 8, 9, with a yarn balloon 10 being formed during the winding, and with the spindle 12 upon which the spool 11 is mounted rotating with a constant rotary speed.
The winding action results from relative movement between the spindle 12 and the traveller 9. This relative movement results from the fact that, during spindle rotation, the traveller 9, as a result of frictional engagement with the ring 8, and as a result of the air resistance of the traveller 9, and also as a result of the air resistance of the yarn balloon 10, lags behind the spindle 12, i.e., turns at a lower rotary speed.
The winding of the yarn onto the spool 11 mounted on rotating spindle 12 proceeds from the bottom up, beginning with the yarn layers which form a conical portion, so that the yarn, in the event the yarn is to be further processed, can be pulled off the winding spool (cop) 11 at high speed.
In order that the yarn be wound onto the cop 11 in the illustrated manner, the ring rail 13 must rise and descend during the winding. To effect formation of a body of yarn wound on the cop 11 in the illustrated manner, it is accordingly necessary to continuously shift the ring rail in upwards direction, or else to continuously shift the spindle mounting structure 14 in downwards direction.
The drive motor 15 for the spindle 12, possibly serving also as the drive for the drawing mechanism 5 through the intermediary of a non-illustrated transmission, can be an A.C. or D.C. motor of the variable-speed type, and if desired of the regulated-speed variable-speed type.
For a constant rotary speed of the drive 15, fine yarn will be supplied from the outlet end of the drawing mechanism 5 at a velocity which is likewise constant. Accordingly, there devolves upon the traveller 9 the task of compensating for the diameter variation of the body of yarn wound on cop 11, which it achieves by travelling at a varying speed. A supplemental compensatory action results from the varying configuration of the yarn balloon 10 during the course of the complete winding of yarn onto the spool 12. The traveller 9, when it is located at the upper nose of the cop, has the lowest rotary speed, and accordingly in this situation the yarn tension is at the highest during this period of the winding.
Reference numeral 32 denotes a suction and blow-off arrangement.
According to the invention, and as schematically depicted in FIG. 3, there is associated with the ring traveller 9 a proximity detector, for example a photoelectric proximity detector comprised of a light source 16 and a photoelectric element 17 so arranged that the reception by receiver 17 of light from source 16 is interrupted during passage of the ring traveller 9 between these components. The photoelectric element 17 generates an electric pulse each time the ring traveller 9 passes between components 16 and 17. Connected to the output of photoelectric receiver 17 is the input of a pulse evaluation circuit 18. The evaluation circuit 18 receives the pulses from photoelectric element 17, shapes these pulses, and most importantly detects when pulses have ceased to be generated. When pulses have ceased to be generated, the pulse evaluation circuit 18 generates a yarn-breakage-indicating pulse, which is registered within circuit 18, for example by means of a counter. The counter is read out and reset at regular predetermined time intervals, for example once per minute. The count read out from the counter is registered on a register and represents the number of yarn breakages occurring, for example, per minute. This registered count constitutes the output signal of the pulse evaluation circuit 18. The output signal of circuit 18 could alternatively be an analog voltage or current.
This output signal, indicative for example of the number of yarn breakages occurring per minute, is transmitted, if necessary via a rectifier stage 19, to one input (or a corresponding set of inputs if the signals in question are all binary-coded, for example) of a comparator 20.
The comparator 20 is also supplied with a reference signal, which can be in binary-coded or other digital form, or can be in the form of an analog voltage or current, which is compared with the value of the controlled variable--i.e., the controlled variable here being directly the yarn travel speed and indirectly the number of yarn breakages occurring per unit time. Any indication of a deviation resulting from this comparison is represented as a signal, and this signal is applied to an amplifier 21 which generates a compensation signal, which is applied to the compensation stage 22 which is operative for changing or causing a change of, for example, the rotary speed of the drive motor 15.
As can be seen from the schematic circuit diagram of FIG. 4, the block designated with numeral 23 symbolically represents the controlled variable, namely the yarn travel speed. The change in the number of yarn breakages occurring per unit time is symbolically represented as an interference or disturbance signal input, since changes in the number of yarn breakages occuring per unit time have an effect upon the average yarn travel speed. Reference numeral 24 designates a measuring station, at which the components 16, 17 of FIG. 3 are located. The output signal of the measuring station are applied to the aforementioned pulse evaluating circuit 18, which may for example be essentially comprised of means for generating a breakage-indicating pulse in response to interruption of the pulse train furnished by measuring station 24, with these breakage-indicating pulses being used to gate a charging transistor 25, so as to cause a voltage buildup across the capacitor 33 corresponding in magnitude to the number of detected yarn breakages, with the capacitor 33 being periodically discharged, for example once per minute, i.e., after periodic sampling of the capacitor voltage prior to discharge thereof.
The regulated variable x (number of breakage-indicating pulses registered per unit time, or equivalently a voltage or current having a magnitude or other characteristic proportional to or indicative of such number) is applied, if necessary via a rectifier stage 19, to a comparator 20. The comparator 20 also receives, from reference value selector 26, a reference value signal w. The comparator or subtractor 20, in the event the values of the signals x and w do not correspond, generates a deviation signal (x-w) which it applies to a servo amplifier 21. The amplifier 21 supplies the corrective signal y to the compensation stage 22. In response to the receipt of such corrective signal y, the compensation stage 22 effects a compensatory adjustment of the adjustable speed control 27, resulting in a compensatory change in the rotary speed of the drive motor 15.
The compensation stage 22 may for example comprise a simple servo motor whose output shaft is connected to the speed-adjustment lever (27) of the drive motor 15, with the servo motor and its transmission exhibiting a conventional proportional-plus-integral input-output transfer function. Alternatively the adjustable speed control 27 might comprise a variable-firing-angle motor-speed-control circuit of the type wherein an electronic switch (such as a triac, or composed of two thyristors connected anti-parallel) is connected in series with the current path of the motor 15, with a first periodic voltage being applied across the motor current path and a second periodic voltage, usually of the same frequency as the first, being applied across the conductivity-control input of the electronic switch, with the phase shift between these two periodic voltages determining the fraction of a period during which motor current flows, and accordingly determining the average flow of energy into the motor 15. If a varible-firing-angle motor-speed-control circuit is employed for stage 27, then the compensation stage 22 could for example comprise a variable phase-shift stage operative for varying the aforementioned phase shift and consisting essentially of a variable impedance, such as a transistor whose conductivity varies continuously in dependence upon the magnitude of the corrective signal y.
Whatever the construction of the stages 22 and 27, the action of the corrective or compensation signal y is such that the rotary speed of the drive motor 15 increases or decreases to such an extent as to cause the number of yarn breakages per unit time to come into coincidence with the number set on selector 26.
Of course, a plurality of such drive motors can be speed-regulated in this manner.
The photoelectric proximity detector 26, 27, or at least a part thereof, can be supported on the fly catcher 28 (FIG. 3) which is anyway present for cleaning of the ring traveller, or can be mounted on any other convenient structure. A gallium-arsenide diode is particularly well suited for use as the light source 16.
Another such control circuit is shown in FIGS. 5 and 6. FIG. 6 depicts, in block-diagram form, a circuit for generating a yarn-breakage-indicating signal. Each time the traveller 9 passes the photoelectric proximity detector 16, 17, a pulse is generated. The illustrated pulse train represents the pulses generated during normal operation; the prolonged zero-value portion following the pulses represents the period during which no pulses are generated because the yarn has broken and is being knotted either manually or by an automatic knotter. These pulses are applied to the toggle (complementing) input of a flip-flop. Each of the two flip-flop outputs is connected to the input of a respective one of two monostable circuits. The outputs of the two monostable circuits are connected to the two inputs of a NOR-gate. Both monostable circuits in FIG. 6 have the same astable-period-duration, and both are dynamically triggered (i.e., are triggered only when the input signal applied thereto changes from 0 to 1). So long as the traveller-synchronized pulses applied to the flip-flop are being generated at a frequency above a minimum frequency determined by the astable-period durations of the two monostable circuits, at least one of the two monostable circuits will always be in the triggered condition. However, if the yarn breaks, for a certain time interval, e.g., during automatic tying of the broken yarn, no pulses will be generated, and both monostable circuits will assume the stable state, i.e., the output signals of both monostable circuits will be 0 signals. This will cause the output of the NOR-gate to become a 1 signal. This 1 signal constitutes a yarn-breakage-indicating signal.
The yarn-breakage-indicating signal generated in FIG. 6 is applied to the F input of a resettable forwards-backwards counter, shown in FIG. 5, F, B and R respectively denoting the forwards-count signal input, the backwards-count signal input, and the reset signal input. The counter is dynamically triggered, i.e., is responsive only to signal transitions from 0 to 1.
The counter in FIG. 5 very simply counts up the number of yarn breakages which occur, for example during a fixed period of time such as 5 minutes or alternatively during the winding of a predetermined number of cops. Each time a filled cop is replaced by an empty cop, the traveller-generated pulses will temporarily cease; this causes generation (by the circuit of FIG. 6) of a yarn breakage signal which is then registered by the counter of FIG. 5. However, a mechanical trip switch, or the like, is provided on the spindle and is tripped when a filled cop is removed. This tripping results in the generation of a cop replacement pulse which is applied to the backwards-counting signal input B of the counter, compensating for the false yarn-breakage-indicating signal just mentioned, so that the count on the counter of FIG. 5 will correspond accurately to the true number of yarn breakages. Actually, the number of cop replacement operations occurring per unit time may be negligible compared to the number of yarn breakages occurring per unit time during optimum machine operation, in which case the just-mentioned compensation can be dispensed with, since the resulting slight inaccuracy in the computed number of yarn breakages will be acceptable.
In any event, the counter in FIG. 5 registers the number of yarn breakages which have occurred. The output of the counter is connected to one input of an AND-gate whose output is connected to the input of a register. A timer periodically (e.g., once per 5 minutes) generates a read-out pulse which it applies to the other input of the AND-gate. As a result, the AND-gate passes the count of the counter to the register, which registers such count, erasing any previously registered count. Persons skilled in the art will understand that while the counter output is shown as a single line connected to a single AND-gate, they may be considered merely symbolic in the event the counter processes signals in binary-coded form; in that event, the counter would for example have a plurality of outputs, for example two for each binary digit, and each output would be connected to one input of a respective one of a corresponding plurality of AND-gates, with the other input of each AND-gate being connected to the output of the timer. Likewise, the outputs of this plurality of AND-gates would be connected to a corresponding plurality of inputs of the register, symbolized in FIG. 5 by a single input line.
The read-out pulse generated by the timer also serves as a counter-reset pulse, being applied to the reset-signal input R of the counter via a short-delay delay stage. This short delay is provided to ensure that the count of the counter is read out before the counter is reset to zero.
In any event, it will be clear that the register will register a new count upon elapse of each preselected time interval, e.g., will register a new count after each 5 minutes or after the winding of 10 cops, or the like.
The count registered by the register is applied to the input of the comparator, in FIG. 5. Again, if the count is expressed in binary-coded form, the single line connecting the register output to the comparator output should be understood to symbolize a set of lines equal in number to the number of binary digits, or to twice the number of binary digits, in per se conventional manner.
Applied to the other input of the comparator, in FIG. 5, is a count equal to the desired number of yarn breakages, e.g., the desired number of yarn breakages per 5 minutes, or the like. Again, this desired number of yarn breakages can be expressed in binary-coded form, in which case the line joining the selector output to the second input of the comparator should be understood to symbolize a set of lines for applying to the comparator a binary-coded number in parallel form. The selector in FIG. 5 is manually settable to the desired number of yarn breakages per unit time.
The comparator has a plus output and a minus output. When the count applied from the register is greater than that applied from the selector, the signal at the plus output is 1 and the signal at the minus output is 0; when the count applied from the register is less than that applied from the selector, the signal at the plus output is 0 and the signal at the minus output is 1; when the count applied from the register equals the count applied from the selector, the signals at both the plus and minus outputs of the comparator are 0 signals.
The plus and minus outputs of the comparator, in FIG. 5, are connected to the inputs of respective monostable circuits. These monostable circuits are triggered dynamically, i.e., respond only to a change from 0 to 1 at the associated comparator output. Each of the two monostable circuits is associated with a respective one of two electronic swithces ES+ and ES-. When one of the two monostable circuits is triggered, it renders and maintains the associated one of the switches ES+, ES- conductive for a predetermined time interval equal to the duration of the unstable state of the monostable circuit. The electronic swithes ES+, ES- are connected in the positive- and negative-current paths of a compensating motor CM. When the switch ES+ is conductive, compensating motor CM is energized with positive current, and its output shaft turns in one direction; when the switch ES- is conductive, compensating motor CM is energized with negative current, and its output shaft turns in the opposite direction. The output shaft of compensating motor CM is mechanically coupled to and controls the movement of the wiper of a potentiometer connected in series with the shunt field winding of the drive motor 15. When the output shaft of the compensating motor CM turns a small distance, the setting of the speed-control potentiometer changes, and accordingly the rotary speed of spindle drive 15 is changed. If the breakage-frequency value registered by the register is greater than that chosen by the selector, the motor drive speed will be reduced by a limited amount. If this limited speed reduction does not bring the breakage frequency down to the selected value, then, in response to the next read-out of the counter in FIG. 5, a further limited speed reduction will be performed. Successive limited speed reductions will be performed until the desired breakage frequency is achieved. Likewise, if the actual breakage frequency is lower than the selected maximum permissible breakage frequency, the drive speed will be increased to a limited extent, in response to each successive read-out of the counter of FIG. 5, until the breakage frequency is brought up to the maximum permissible value.
For generating the yarn breakage signal, instead of the photoelectric proximity detector 16, 17 shown in FIG. 3, use could also be made of a proximity detector of the reflex type. According to a further concept of the invention, the ring 8, in the region of the sliding path of the traveller 9, can be provided with a pressure-responsive but friction- and temperature-resistant element 29, for example a piezoelectric ceramic (FIG. 2). When the yarn is being wound, the ring traveller 9 will exert upon the piezoelectric element 29 a pressure resulting in the generation of a measurable voltage across the piezoelectric element. If the yarn breaks, the ring traveller 9 suddenly ceases to exert such pressure, and the piezoelectric voltage undergoes a sudden change ΔU, which can be amplified and applied to the pulse evaluation circuit 18.
One method of doing this is depicted in FIG. 7. There the ring 9 and piezoelectric element 29 cooperate to generate the aforementioned piezoelectric voltage U, which is applied to the input of a differentiator. Upon yarn breakage, the sudden voltage change ΔU results in the generation at the differentiator output of a voltage spike, for example a negative voltage spike, which is passed by a half-wave rectifier to a Schmitt trigger. If the negative voltage spike is of a magnitude so great as to correspond to the sudden pressure decrease associated with yarn breakage, the Schmitt trigger triggers a dynamically triggered monostable multivibrator which in turn generates a well-shaped pulse constituting the yarn-breakage-indicating signal. The Schmitt trigger is provided to distinguish between high-magnitude voltage spikes associated with yarn breakage, and low-magnitude voltages associated with lesser pressure variations attributable to other causes. The half-wave rectifier is provided to block the voltage spike which is generated by the differentiator when the piezoelectric voltage U undergoes an opposite sudden change, upon resumption of yarn travel.
The yarn breakage signal, whether generated by photoelectric or by piezoelectric means, can be processed in the same manner.
Instead of the proximity detectors already discussed, use could also be made of an air-pressure-responsive proximity detector which, in the event the ring traveller 9 comes to a standstill as a result of yarn breakage, causes a signal to be generated, in a manner analogous to what has been described above, in response to the absence of air flow.
As a further possibility, there can be arranged close to the path of the ring traveller 9 a heat-responsive element 30 (FIG. 3). When the yarn, and accordingly the traveller 9, has been travelling for a period of time, the traveller 9 acquires an elevated temperature as a result of frictional contact with the guide ring 8. The passage of the warm or hot traveller 9 past the heat-responsive element 30 results in the generation of a pulse, in the same manner as did the passage of the traveller 9 between the elements 16, 17 of the photoelectric proximity detector. In the event of yarn breakage, these pulses cease to be generated, constituting an indication of yarn breakage. During automatic or manual tying of the broken yarn, the taveller 9 will of course cool somewhat. Accordingly, upon resumption of yarn travel, the traveller 9 may require some time to reassume a temperature sufficient to be detected by the element 30. This delay can be compensated for by the provision of a time relay.
Finally, use can also be made of capacitive, inductive, or other known types of proximity detectors.
In the event that the number of yarn breakages occurring during the selected time interval is too large only for one or a few of the spindle units of a large spinning machine provided with many spindles, with accordingly the rotary drive speed and yarn travel speed of the one or few spindle units being always below the desired value at which the other spindle units are operating, then it is appropriate to reexamine the yarn characteristics, the operation of the drawing mechanism 5, the centering of the spindle, etc., but particularly the spindle mechanism. This is particularly the case since experience has shown that a relatively low number of spindles are responsible for a very high percentage of all the yarn breakages, and mainly as a result of faulty spindle centering.
To determine which spindle units are producing the most yarn breakages, it is useful to count the number of yarn breakages occurring during a certain time interval absolutely per spindle, so as to be able to then look into the operation of the "offenders".
In this way, it is possible to determine and establish the most economical yarn feed speed for the spinning machine, taking into account the maximum permissible yarn breakage frequency consistent with acceptable quality.
The yarn breakage frequency detector, or the yarn breakage detector thereof, or a plurality of such detectors, can be provided along the length of the whole yarn travel path at suitable locations, particularly in the region of the blow-off and suction arrangement 32 (FIG. 1). In this case, particularly well suited are proximity detectors responsive to air flow changes.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of circuits and constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a yarn-travel-speed control arrangement in a ring spinning machine, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can by applying current knowledge readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | An apparatus is operative for processing yarns, filaments or other such elongated elements. An arrangement for controlling the travel of such elongated element includes a device for determining the number of elements breakages occurring per unit time and for generating a corresponding breakage-frequency signal, a device for establishing a reference breakage frequency, and a mechanism for automatically varying the speed of yarn travel as a function of the discrepancy between the reference breakage frequency and the breakage frequency indicated by the breakage-frequency signal. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from European patent application No. 10 163 520.9-2213 filed on May 21, 2010, all of which is incorporated herein by reference in its entirety for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates to a floating noise reduction system for moving and/or falling fluids, the process for manufacturing of such system and the use of such system.
BACKGROUND OF THE INVENTION
[0003] Falling or dropping and flowing fluid, especially water, is known to create significant noise that becomes a health and safety concern for work personnel and a nuisance for nearby residents. A prominent case is in cooling towers of power plants where costly measures have to be taken to reduce the noise. The conditions in cooling towers are among the worst for any sound dampening installation, as there is a permanent high water impact like from a waterfall moving round in circles. The resulting force can cause severe damage or at least accelerated fatigue to installations of any kind. Additionally, there has to be appropriate, i.e. highly efficient, drainage as any sound damping installation of course has to work above the water surface situation at the base of the tower. Thus, if a system can work under cooling tower conditions it is likely to work everywhere, e.g. also when applied on flowing fluids.
[0004] Some scope in sound attenuating systems has been put on cooling tower noise reduction for a.m. reasons. As the most widespread method, a noise protection wall around the base of the cooling tower is 1. costly and 2. only will reduce the noise emitted at ground level but not the noise escaping through the top opening, other measures had been examined. One approach consists in applying grid-like or mesh-like systems that should disperse the water flow and the noise, subsequently, such as in CN 200972335, CN 100533033, CN 2341088 and CN 2453381. The claimed noise reduction of 15-30 dB of the latter could not be reproduced during our examinations. Honeycombs as damping elements are mentioned in CN 2823955 and CN 1862206, but honeycombs or hollow systems in general are notorious for creating resonance sound, or “drumming”, of course. All the a.m. systems are mainly based on metalwork and/or rigid plastics and thus do not possess material immanent dampening properties. To improve that situation, JP 8200986 claims the use of a combination of water permeable and non-permeable synthetic resin mats, however, also those materials are rather rigid and the drainage properties—despite the claimed drainage ridges—are poor, leading to water agglomeration on top of the mat which will increase the noise level again. CN 2169107 mentions damping mats and particles; however, the claimed system is not able to provide sufficient structural integrity for the application. Another approach is focussing on plate systems where the plates themselves are supported by a damping device and also disperse water, such as in CN 201003910, CN 201302391, CN 201302392, CN 201302393, CN 201184670, CN 1945190 (all describing combinations of rotating and fixed plates, partially combined with pipe systems), CN 201311202 (microporous plates), CN 2821500 (plates, rings and surface structures as known from acoustic indoor systems), JP 56049898 (complex metalwork with damping inlays). Other systems described in the literature are: CN 2447710 and CN 2438075 (use of floating balls) and CH 451216, DE 3009193, DE 1501391, DE 2508122, EP 1500891, SU 989292. The latter documents, as well as a publication (M. Krus et al: Latest developments on noise reduction of industrial induced draft cooling towers, Veenendaal, 2001, pp 33-38) all mainly refer to systems consisting of floating devices which are supporting or carrying the damping system, consisting of mat-like structures, means, some elasticity or flexibility has been acknowledged to be beneficial for sound dampening; JP 58033621 at last mentions that “soft cover” may reduce falling water noise (for sluice doors). However, those systems are not consequently using the potential of elastic dampening and exhibit deficiencies in floating properties as well as in drainage performance; and some systems again are sensitive to mechanical impact.
SUMMARY OF THE INVENTION
[0005] A major object of the present invention thus is to provide a floating noise reduction system or material combination not showing the above mentioned deficiencies but exhibiting a significant and sustainable level of noise reduction over all concerned frequencies and showing an additional drainage effect and high mechanical wear resistance.
[0006] Surprisingly, it is found that such system or material not showing the above mentioned disadvantages can be made from a combination of expanded elastic material with a floating mechanical support made from expanded polymer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] In the accompanying drawings,
[0008] FIG. 1 schematically illustrates the composition of claimed system,
[0009] FIG. 2 schematically illustrates the skeleton (reticulated) structure,
[0010] FIG. 3 schematically illustrates the damping of flowing or falling fluid or waves,
[0011] FIG. 4 schematically illustrates the possible surface structures for drainage and absorption for layers (A) and (B),
[0012] FIG. 5 schematically illustrates the test layout for falling water noise detection, and
[0013] FIG. 6 shows the frequencies being damped by claimed materials: ⅓ octave band spectra resulting from falling water test.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The claimed material comprises at least one layer (A) of expanded polymer based material with open cell (open porosity) structure ( FIG. 1 ). The polymer based material of (A) can be expanded from an elastomer and/or thermoplastic elastomer (TPE) and/or thermoplastic and/or thermoset based polymer mixture, or combinations thereof, and can optionally be crosslinked to improve mechanical (e.g. compression set) and wear properties. Preferred are polymer based materials providing elasticity to (A), either by elastic properties provided by the polymer itself (e.g. for elastomers and TPEs) or by respectively thin, thus flexible expanded structures, or by a combination of both. The polymer based material is expanded by physical and/or chemical expansion agents to an open cell sponge or reticulated (skeleton) structure, depending on the required damping and drainage properties. Preferred is a reticulated (skeleton) structure where the polymer based cell walls are reduced to columns showing a diameter thinner than the average cell diameter (see FIG. 2 ). The polymer based material can be a mixture or compound that may contain fillers, such as oxides, carbonates, hydroxides, carbon blacks, recycled (ground) rubber, other recycled polymer materials, fibres etc., and additives, such as flame retardants, biocides, plasticizers, stabilizers, colours etc., of any kind in any ratio. The polymer base mixture may be crosslinked by any applicable mean of crosslinking, such as sulphur, peroxide, radiation, bisphenolics, metal oxides, polycondensation etc. (A) can show various densities, preferred are densities lower than typical fluids, e.g. lower than 700 kg/m3, to prevent sinking even when fully soaked. Especially preferred are densities lower than 300 kg/m3. It is easily feasible to use various combinations of polymer based compounds and various combinations of layers (A) made thereof. (A) will quickly absorb the falling or flowing fluid, disperse its impulse into smaller drops and in parallel will disperse the resulting impact energy transversally into the matrix of (A). This dispersion will continue through the open cell structure and into layer (B) and finally will lead to noise absorption within the claimed material and transmission of remaining noise into the fluid underneath when damping falling fluid, or into the medium above or outside when damping flowing fluid, or into a lateral medium when damping e.g. waves (see FIG. 3 ). Meanwhile the absorbed fluid itself will be silently drained through (A) and (B) to the fluid underneath or into the medium above or drained laterally. Layer (B) thus not only acts as floating and draining part of the system, but supports the noise reduction by interaction with (A) and by providing further potential for damping additional frequencies. (A) can be of flat surface to the falling fluid, or it can be structured to alter the absorption/dispersion properties, and it can be equipped with e.g. pin holes for better drainage. (A) can also be structured on its face to (B) for same reason, e.g. for drainage or sound decoupling purposes (see FIG. 4 ). Preferred materials for the manufacturing of (A) are elastomers, such as NR, IR, SBR, NBR, CR, IIR, EPM, EPDM, Q, etc., thermoplastic elastomers, such as TPP, TPV, TPU, SAN, SEBS etc., PIR/PUR or polyurethanes, especially reticulated polyurethanes, polyesters, phenolic and melamine based compounds.
[0015] The claimed system comprises at least one layer (B) of expanded polymer based material different or same as for (A) with either open or closed cell structure ( FIG. 1 ). The polymer based material of (B) can be expanded from an elastomer and/or thermoplastic elastomer (TPE) and/or thermoplastic and/or thermoset based polymer mixture, or combinations thereof, and can optionally be crosslinked to improve mechanical (e.g. impact strength) and wear properties. Preferred are polymer based materials providing structural integrity to (B) to prevent breaking or warping of the system. The polymer based material is expanded by physical and/or chemical expansion agents to an open cell sponge or closed cell foam, depending on the required mechanical, damping and drainage properties. Preferred is a minimum 50% closed cell structure, especially preferred are at least 70% closed cells to prevent soaking and saturation with fluid. The polymer based material can be a mixture or compound that may contain fillers, such as oxides, carbonates, hydroxides, carbon blacks, recycled (ground) rubber, other recycled polymer materials, fibres etc., and additives, such as flame retardants, biocides, plasticizers, stabilizers, colours etc., of any kind in any ratio. The polymer base mixture may be crosslinked by any applicable mean of crosslinking, such as sulphur, peroxide, radiation, bisphenolics, metal oxides, polycondensation etc. (B) can show various densities, preferred are densities significantly lower than typical fluids, e.g. lower than 500 kg/m3, especially preferred are densities lower than 200 kg/m3. It is easily feasible to use various combinations of polymer based compounds and various combinations of layers (B) made thereof. (B) comprises a structure to ensure good drainage properties as (B) is responsible to draw the fluid away from (A) into the fluid underneath. This structure can comprise pin holes that can be applied in a wide variety of size and pattern and combinations. The structure can also comprise ridges of any shape in any combination (e.g. triangular, sinus-like, rectangular, trapezoidal etc.) that can be applied on one or both surfaces of (B) (see FIG. 4 ). (B) can be fixed to (A) by mechanical means, or chemically by bonding, or by a combination of both. Layers (A) and (B)—and optionally (C)—can be brought together directly by co-forming, e.g. by co-extrusion and/or co-moulding and/or lamination, and/or can be connected after giving shape to them. The connection can be achieved by adhesives, e.g. one or two part silicone, polyurethane, acrylate, chloroprene, contact adhesives or hot melts or any combination thereof. Or the connection can be achieved by direct melting or welding the two materials together, such as by UHF welding or the like. The preferred final form is a mat or tile like multilayer compound system. The tiles can easily be cut and shaped to fit any geometry of the fluid basin or fluid track to float on. Preferred materials for the manufacturing of (B) are elastomers, such as NR, IR, SBR, NBR, CR, IIR, EPM, EPDM, Q, etc., thermoplastic elastomers, such as TPP, TPV, TPU, SAN, SEBS etc., PIR/PUR or polyurethanes, polyesters, phenolic and melamine based compounds. Especially preferred are compounds providing high impact strength, such as polyalkylidene terephthalates.
[0016] The claimed material furthermore may comprise one or more additional layers (C) within and/or between layers (A) and/or (B) that may provide additional drainage and/or damping and/or other properties, such as preferably reinforcement, impact resistance etc. The layers (C) can e.g. comprise fibres, e.g. as mesh, or nonwoven, wire mesh, resin sheet etc. of any kind; see FIG. 1 .
[0017] The claimed material furthermore may comprise a link system (D) that connects individual pieces, e.g. tiles, comprising layers (A), (B), and optionally (C) together, but still leaving room to move and float. (D) can comprise metalwork, woven bands, elastic links etc., or a combination thereof. (D) is fixed either into layer (B)/(C)—as the structurally toughest ones—or into the system, i.e. (B), from underneath or above or by a combination of both methods. Care has to be taken that (D) will not negatively influence the floating properties (weight) and the flexibility of the whole system. Cardan joints or axle bearing based links or other flexible linking methods are therefore preferred. An accordingly strong layer (C) between (A) and (B) can also take the part of (D) if the pieces of (A) and (B) are connected onto (C) keeping some distance between the respective tiles. However, a connection system (D) is preferred where individual tiles can be easily exchanged, e.g. for maintenance purposes.
[0018] It is a prominent advantage of the claimed material that it is providing excellent damping together with draining effect due to its composition and structure and that it additionally shows built-in anti-fatigue properties due to its composition, allowing long-term use even under harsh conditions.
[0019] A further advantage of the claimed material is the possibility to adapt its properties to the desired property profile (concerning mechanics, damping/absorption, fluid intake, hydrophilic or hydrophobic character, porosity etc.) This can be achieved by modifying the expansion agent(s), the expansion process and the polymer base material composition, as well as the density, and, if required, the crosslinking system(s). The material thus can be altered to damp/absorb from high to low frequencies or frequency bands (see FIG. 6 ), and it can be used in contact with a broad variety of fluids, including aggressive and/or hot or cold ones.
[0020] Another basic advantage of the claimed material is the fact that its noise reduction properties are very constant over a wide temperature range leading to the fact that its performance remains unchanged no matter if it is used in summer or wintertime.
[0021] It is a further important advantage of the claimed material that it will reduce both the ground level noise as well as the top level noise at cooling towers (see table 1 and FIG. 6 ), rendering noise protection walls obsolete.
[0022] It is another important advantage of the claimed material that it can be applied for noise reduction both of falling/dropping and flowing fluids.
[0023] It is another advantage of the claimed material that it is environmental friendly as it does not comprise or release harmful substances, does not affect water or soil or nature in general and as it is recyclable by separating the layers and then grinding or melting them individually.
[0024] A resulting advantage of the material is the fact that it can be blended or filled with or can contain scrapped or recycled material of the same kind to a very high extent not losing relevant properties significantly, which is especially the case for (B) and (C).
[0025] It is another advantage of the claimed material that its expanded structure provides insulation properties, thus, it can be beneficial for keeping fluids warm or cold in addition to the damping properties.
[0026] It is a prominent advantage of the claimed material that it can be produced in an economic way in automatic or semi-automatic shaping process, e.g. by moulding, extrusion and other shaping methods. It shows versatility in possibilities of manufacturing and application. It can be extruded, co-extruded, laminated, moulded, co-moulded etc. as single item or multilayer already and thus it can be applied in almost unrestricted form.
[0027] It is a further advantage of the claimed material that it can be transformed and given shape by standard methods being widespread in the industry and that it does not require specialized equipment.
[0028] It is another advantage of the claimed material for the application that it is long-lasting and durable, however, easy to change in case of maintenance and thus will reduce running costs for the user.
EXAMPLES
[0029] Preparation of Test Samples
[0030] 1. Floating layer (B): an extruded, expanded and cut PET board of 25 mm thickness and 1000×1000 mm width (ArmaStruct®, Armacell, Münster, Germany) was coated with a silicone adhesive layer (ELASTOSIL® R plus 4700, Wacker Chemie, München, Germany) to give the floating part of the system. A sinus shape ridge structure (distance peak to peak of 35 mm) was applied to one surface by thermoforming embossing and pin holes of 20 mm diameter were drilled into the board in a distance of 80 mm.
[0031] 2. Sponge like open cell absorbing layer (A): A rubber compound (Armaprene® N H, Armacell, Münster, Germany) was extruded, expanded and cut to an open cell foam mat of 25 mm thickness and 1000×1000 mm width and then laminated onto the plain surface of (B) as single or double layer by heating the composite up to 120° C. in a hot air oven, using the a.m. adhesive.
[0032] 3. Skeleton structure open cell absorbing layer (A): A reticulated polyurethane foam mat of the type 80 poles per inch (SIF®, United Foam, Grand Rapids, U.S.A.) of 25 mm thickness and 1000×1000 mm width was laminated onto the plain surface of (B) as single or double layer by heating the composite up to 120° C. in a hot air oven, using the a.m. adhesive.
[0033] Experimental Setup
[0034] The experiments were carried out on test equipment proposed and developed by the University of Bradford, UK (Prof K. Horoshenkov). The setup (see FIG. 5 ) comprised of a large underfloor concrete water tank. The tank was 2.5 m deep, 1.8 m wide and 2.35 m long and was able to hold approximately 8 m3 of water. The water was discharged onto the underfloor tank from a perforated water tank mounted above. The perforated water tank was made of PVC and its dimensions were 0.55 m wide×0.55 m long×0.2 m deep. In order to simulate the discharge typical to that measured in a cooling tower the perforated water tank had 243 holes all 1 mm diameter wide drilled in a 5 mm thick base, the spacing between the perforations was approximately 26 mm. The size of the perforations was chosen in accordance with the ISO 140, Part 18 (2006) and corresponds to that required to generate heavy rain. The perforated water tank was calibrated to deliver 5 m3/m2/hr discharge. This required a water supply at the rate of 20.8 litres per min. The calibration was carried out by using a standard flow meter and by weighing the amount of water discharged from the hose pipe over 15 sec intervals. It required the PVC water tank to be filled with 180 mm of water to achieve the equilibrium between the water pick-up and runoff.
[0035] The absorber foam samples (A) were tested in single and double layer configurations placed on top of the floating layer (B) by adhesion as described above. The distance between the top surface of the top foam layer and the bottom of the perforated water tank was kept 2 m in all the experiments to ensure the same terminal velocity of the water droplets. The following items of equipment were used for sound recording and analysis:
[0036] (i) one PC with WinMLS 2004 build 1.07E data acquisition and spectrum analysis software and 8-channel Marc-8 professional sound card.
[0037] (ii) four calibrated Bruel and Kjaer microphones, ½″ type 4188.
[0038] (iii) one 4-channel B & K Nexus conditioning amplifier type-2693 set at 1V/Pa.
[0039] The audio channels were calibrated to 94 dB using a standard B&K microphone calibrator (Type 4230, no: 1670589). The ⅓-octave sound pressure level spectra were measured on the four channels and used to calculate the mean ⅓-otave level spectrum and the broadband sound pressure level (see FIG. 6 ). The lateral positions of the four microphones in the underfloor water tank are shown in FIG. 5 . The microphones were suspended on cables 0.8 m below the bottom of the perforated water tank. The level of ambient noise in the laboratory was very low and signal to noise ratio of better than 20 dB was ensured throughout the tests.
[0040] Results
[0041] Table 1 shows the good damping properties of already a standard sponge structure open cell material. The noise reduction effect even gets much better when very open cell (“skeleton structure”) material is applied. Another incremental improvement can be found in a combination of both.
[0000]
TABLE 1
Falling water test: noise reduction of open cell materials (A) -
SpC = Sponge-like open cell structure; SkC = Skeleton-like
open cell structure - in 25 and 50 mm thickness applied on
a given layer of (B) in comparison with the unarmed water surface
(all innovative examples).
Avg. sound pressure
Type of layer (A)
level (dB)
Noise reduction by dB
SpC foam 25 mm
68.4
8.2
SpC foam 50 mm
67.6
9.0
SkC foam 25 mm
54.5
22.1
SkC foam 50 mm
54.5
22.1
SkC + SpC (25 + 25 mm)
52.6
24.0
No damping
76.6
n.a.
[0042] The frequencies being damped or absorbed also give an indication about the performance of the materials and material combinations. FIG. 6 shows the ⅓ octave band spectra for the materials of table 1 and proves that the skeleton like structure also has advantages in damping a broader range of frequencies (the sponge like structure tends to boom at low frequencies), however, it can be found, too, that a combination of both materials is performing slightly better. | The present invention relates to a floating noise reduction system for moving and/or falling fluids, the process for manufacturing of such system and the use of such system. | 6 |
FIELD OF THE INVENTION
The instant invention relates to the field of dishwashers, and in particular, to a liquid detergent dispenser for automatically inserting a predetermined amount of detergent into a dishwasher.
BACKGROUND OF THE INVENTION
Dishwashers have become indispensable modern day appliances. The appliances eliminate the burden of washing and drying eating utensils by use of a chamber capable of automatically performing such tasks. A further advantage of the dishwasher is that the chamber provides a storage location for soiled eating utensils thereby economizing the washing process to provide the use of water and detergent efficiently.
As with any cleaning process, there exists a need for adding a detergent which acts as the mechanism for loosening embedded food particles. While conventional dishwashers include various mechanisms to dispense detergent at the proper time, a problem with such dishwashers is the inability to monitor and dispense an accurate amount for any particular dishwashing cycle. Some dispensers may employ markings to indicate to the homeowner the preferred amount of detergent before the washing cycle begins. These markings are hard to see, highly inaccurate, and nearly impossible to level off the detergent to the desired level marking. Most users therefore, fill the dispenser to the top and even overfill each time. When liquid detergent is used, it must be added right before the dishwashing cycle begins as liquid detergent has a tendency to leak out of the container causing interference with dispenser operation and lessening the effectiveness of the cleaning cycle. When granular detergent is used it must be added just before the dishwashing cycle begins, or the granular detergent tends to cake in the dispenser and does not thoroughly dissolve until sometime into the rinse cycle. Further, adding of detergent is easily forgotten when numerous members of a household are adding utensils to the dishwasher chamber. The individual who turns on the dishwasher may forget to add the necessary detergent thinking another performed the chore. In this situation the dishwasher goes through a complete cycle without any cleaning what-so-ever, only a rinsing. If the individual whose task it is to unload the dishwasher does not observe that the dishwasher went without detergent, but instead thinks that perhaps just some of the utensils did not come out very clean, the cooking utensils, dishes, etc. will be put away unclean and possibly even put away with harmful bacterial contamination on every item in the dishwasher.
Conventional detergent dispensers also present a problem most evident to those attempting to economically purchase liquid detergent in a bulk quantity. The lifting of a large volume container of fluid can cause injury to the elderly, small children, or the like individual who might be slightly physically impaired. The manual filling of door mounted dispensers requires the individual to balance the container while attempting to determine how much detergent should be placed within the dispenser.
The inefficiency also leads to a waste of detergent sending excess surfactants to discharge which inhibits both municipal and septic containers. In addition, excess detergent can damage glassware and fragile utensils as many liquid detergents have a high pH which is caustic. Liquid detergent may also contain sodium hypochlorite which is dangerous to store even temporarily especially in door-mounted dispensers and can burn infants or those people having tender skin. Thus, the amount of detergent used is critical to health, safety, operation, and the environment.
U.S. Pat. No. 3,370,597 discloses a dishwashing machine with a liquid sanitizer dispenser. The dispenser includes a motor driven pump and spray device incorporating a gravity fed pump with an integrated solenoid and dispensing valve. The main purpose of the device is to inject chlorine into the dishwasher for disinfection of the eating utensils. Cycling of the injection system is independent of the detergent dispensing cycle.
U.S. Pat. No. 3,749,288 discloses a liquid dispenser integrated into a wall of a dishwasher for inserting a wetting agent to assist the washing cycle.
U.S. Pat. No 5,282,901 discloses a removable liquid dispenser for inserting detergent into an industrial warewash machine. A probe is placed into the wash chamber for monitoring the conductivity of the wash water. The warewash chamber maintains a volume of water wherein the conductivity provides a relationship to water quality. The device is complicated and not suited for residential purposes, nor does it have the ability to monitor the amount of liquid detergent left in the supply container, or stop the machine from going through a wash cycle when there is no detergent available.
Thus, what is lacking in the art is a detergent dispenser that can be incorporated into a conventional dishwasher having the ability to automatically dispense liquid detergent from either an independent container or by use of an integrated reservoir, said dispenser including an ability to monitor the amount of detergent dispensed, the ability to monitor the amount of detergent left in the container before running out, and the ability to stop the machine from operating when there is no detergent available to be dispensed.
SUMMARY OF THE INVENTION
The instant invention discloses an apparatus for injecting detergent into a conventional residential dishwasher. In a preferred embodiment, the apparatus consists of an electric pump which operates on a timer used in conjunction with an existing dishwasher wherein the pump transfers liquid detergent from a container through the side wall of a dishwasher. The apparatus is energized/triggered by the same electrical impulse that triggers the currently used door-mounted detergent dispenser, thereby providing detergent at the proper time. The apparatus couples to the dishwasher water inlet solenoid which then allows transfer of fresh water to the dishwasher only when there is adequate detergent available to be dispensed. The apparatus includes a means for deenergizing the water inlet solenoid should the pump's sensing mechanism determine that an inadequate amount of detergent exists in the detergent container. The sensing mechanism and a suction tube is placed into an independent detergent container positioning both tubes along a bottom portion of the container for drawing of the detergent and monitoring its contents. An upper aperture provides venting of the container preventing collapse of the container as fluid is drawn.
The tubes are incorporated into a cap to simplify setting up the system allowing the cap to be easily exchanged for an existing cap. The tubes are placed into a container of liquid detergent by simply removing the packing cap and threading on the modified cap of the instant invention.
The pumping mechanism utilizes a timer allowing an individual to set the amount of detergent to be dispensed. Predetermined settings allow an individual to quickly determine the amount of detergent to be dispensed. A self cleaning dispersion valve placed in the dishwasher prevents back flow of water to prevent diluting of the detergent and is self-cleaned during the wash cycle.
An alternate embodiment of the invention positions a storage container beneath the dishwasher allowing the consumer to internally fill the container. A benefit is the space saving feature and the ability to use low cost detergent packs. In addition, by providing a container with the instant invention, various liquid level monitoring mechanisms can be used.
In all embodiments, a sensor determines whether the liquid level within the container has fallen to a point that requires replenishment and alerts the user to this condition by use of a light and of an alarm mechanism. A solenoid trigger allows three additional wash cycles providing the homeowner with ample opportunity to replenish the detergent before it is completely exhausted. After the third wash cycle, the pumping mechanism's sensor discontinues the supply of electricity to the water inlet solenoid, thereby preventing the start of another wash cycle. When the user replenishes the supply of detergent, the pumping mechanism's sensor reconnects the electrical supply to the water inlet solenoid and normal dishwasher operation can resume. The instant invention allows for the modification of dishwasher design to include a detergent level monitor on the panel, as well as contemplates the operation of the pumping mechanism controls from the front panel of the dishwasher. It can be noted that the system also allows for the insertion of a small amount of detergent at the end of a cycle which acts as an air freshener.
Thus, an objective of the instant invention is to provide an automatic liquid detergent dispenser for use in combination with a new or existing dishwasher providing efficiency in detergent dispersion.
Another objective of the instant invention is to disclose an automatic detergent dispenser capable of utilizing existing liquid detergent storage containers.
Still another objective of the instant invention is to disclose a method of monitoring the level of liquid in a detergent container, including a means for detection of a low level condition providing both visual and audible indication of the level.
Yet still another objective of the instant invention is to provide additional wash cycles once a low liquid level is detected thereby allowing a homeowner sufficient time to replenish the detergent.
Yet still another objective of the instant invention is to incorporate a liquid detergent transfer pump together with a water inlet solenoid so as to provide a shut off of the water should an inadequate amount of detergent be available.
Yet still another objective of the instant invention is to position a detergent storage container in an open space beneath the dishwasher for optimum space use. Refilling of the container is accomplished by use of a side mounted access tube fluidly communicated with the storage container.
Yet another objective of the instant invention is to disclose a self-cleaning detergent fill, injection, and vents capable of maintaining a heightened level of moisture in the system to prevent detergent thickening.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of the preferred embodiment of the instant invention drawing from a conventional liquid detergent container;
FIG. 2 is a pictorial view of an alternative embodiment having an integrated storage container;
FIG. 3 is a pictorial view of an embodiment employing a remote storage container;
FIG. 4 is a pictorial view of a remote storage container being filled from a soft walled liquid dispenser;
FIG. 5 is a pictorial view of an embodiment having a remote storage container with multiple sensors;
FIG. 6 is a pictorial view of a mechanical liquid level indicator used in conjunction with a sensing mechanism in a remote storage container;
FIG. 7 is a perspective view of a side wall fill port;
FIG. 8 is a perspective view of the fill port shown in FIG. 7 in an open position and a fill tube positioned therein;
FIG. 9 is a cross-sectional side view of FIG. 7;
FIG. 10 is a perspective view of the liquid dispenser delivery mechanism;
FIG. 11 is a pictorial view of FIG. 10 illustrating detergent delivery;
FIG. 12 is an exploded view of FIG. 10;
FIG. 13 is a cross-sectional side view of FIG. 12;
FIG. 14 is a perspective view of an alternative embodiment for detergent dispensing;
FIG. 15 is a cross-sectional side view of FIG. 14;
FIG. 16 is a perspective view of the liquid detergent container vent;
FIG. 17 is a cross-sectional side view of FIG. 16 with the vent shown in a closed position;
FIG. 18 is a cross-sectional side view of FIG. 16 with the vent shown in an open position;
FIG. 19 is a front view of dishwasher control panel incorporating pump controls on the facade of the dishwasher panel, and a systems monitor to indicate detergent level.
DETAILED DESCRIPTION OF THE INVENTION
Although the present invention is herein described in terms of a basic embodiment, it will be readily apparent to those skilled in this art that various modifications, rearrangements, and substitutions can be made without departing from the spirit of the invention. The scope of the present invention is thus only limited by the claims appended hereto.
Now referring to FIG. 1, set forth is a pictorial view of a conventional residential kitchen depicting a cabinet 100 supporting a utility sink 102 adjacent to a dishwasher 104. The apparatus of the instant invention consists of a pump 10 that is operated on electricity as illustrated by electrical cord 12 inserted into wall socket 106, wherein the pump 10 is placed within a housing 14 having a timing mechanism such as a potentiometer or the like control switch 16 that permits the pump to run for a predetermined amount of time. A "light" setting 18 allows the pump to run at a minimal amount of time delivering only a small amount of detergent, perhaps 1/2 oz when regular water supply is "soft". A "normal" setting 20 allows the pump to operate a predetermined period of time to allow the pump to transfer an amount of liquid detergent into the dishwasher, perhaps the 11/4 A oz. typically required for an average dishwashing cycle and, an "extra" setting 22 provides pump operation leading to an additional amount of detergent transferred, perhaps 2 oz. for those instances where the dishwasher is expected to clean an oversized load, or when "hard" water conditions are present.
The transfer means is a pump 10 which is fluidly coupled to a liquid detergent storage means, capable of holding at least one pint of liquid, in this instance a container 108 wherein the shipping cap, not shown, is removed and replaced with a modified cap 24 having four apertures allowing detergent removal. A first aperture is coupled to tube 26 which is juxtapositioned a small distance from the bottom wall of the container 108 and allows for liquid detergent transfer through pump 10 outward through delivery tube 28 into injection fitting 30 mounted through the side wall of dishwasher 104. A second tube 32 allows liquid detergent transfer from container 108 through pump 10 and returns the detergent through return tube 34. This operation allows for continuous liquid sensing.
When the level of detergent drops beneath the entry opening 36 of the second tube 32, a sensor determines lack of fluid providing an alarm to indicate that the liquid container 106 is low on detergent. Alarm indication is provided by a light 38 located on the facade of the pump housing and having an audible alarm 40. Vent 42 is provided for aspiration to prevent collapse of the container while liquid detergent is being withdrawn.
The pump 10 is electrically coupled to the existing detergent drawer 112 of the dishwasher to initiate pump operation at a time predetermined by the manufacturer of the dishwasher. Water inlet solenoid 46 is electrically coupled to the liquid level sensing mechanism so that when a low level of liquid detergent is sensed, three additional washing cycles are allowed and then water inlet solenoid 46 is disconnected electrically thereby preventing any additional wash cycles until detergent is replenished.
Referring to FIG. 2, an alternative embodiment of the invention illustrates the pump 10 with the aforementioned control switch 16, coupled to a storage container 50. Pump 10 is operated on 120 VAC as provided by electrical cord 12 inserted into wall socket 106 having a DC step down transformer allowing direct pump control. In this embodiment the storage container 50 accepts a manual refill of detergent with a fill. port aperture 52 allowing insertion of liquid detergent. The fluid level is visually determined by indicator 54 which operates via a well known twist rod float 56 mechanism. It should be noted that the storage container 50 may be made of translucent material thereby eliminating the need for a visual float indicator as the level may be determined by viewing through the side wall of the storage container 50.
Operation of this embodiment remains similar to the previous embodiment by positioning the apparatus within an open cabinet 100 next to a dishwasher 104. The operation of the pump 10 is initiated by detergent drawer 112 electrically coupled by cable 44 to the pump controller mechanism. In addition, inlet solenoid 46 is electrically coupled to the apparatus providing a delayed shut off of water if an insufficient amount of detergent exists within the storage container 50.
In operation, suction tube 58 is juxtapositioned along bottom wall of storage container 50 providing an inlet for the pumping mechanism with outlet tube 28 coupled to injection fitting 30 placed through the side wall of dishwasher 104. A tube opening 60 assists in determining the fluid level within the container by providing an indicator to the pump 10 when the level of liquid detergent falls below the aperture opening. As with the previous embodiment, inadequate fluid level operates light 38 and audible alarm 40 so as to provide an indication to the homeowner of a low level condition. In addition, as previously mentioned, the apparatus provides approximately three additional dishwasher cycles once the liquid has fallen below tube opening 60 before disengaging inlet solenoid 46. It will be obvious to one of ordinary skill in the art that the amount of dishwashing cycles after the fluid falls beneath the low level pick up may be adjusted in accordance with the size and shape of the liquid detergent container and the detergent setting, i.e., LT.--NOR.--EXTRA. Vent 62, described later in the specification, prevents collapse of the storage container 50 as the pump 10 draws detergent from the chamber.
Now referring to FIGS. 3 and 4, set forth is an alternative embodiment of the instant invention having a container 70 remotely located beneath dishwasher chamber 114. An alternative sensing mechanism 72 may consist of an electrode for detecting the level of liquid within the container 70. Suction tube 74 is fluidly coupled to pump 76 which transfers liquid through dispensing tube 78 into dispensing mechanism 80 placed in the side wall of the dishwasher chamber 114. Filling of the container 70 is provided by aperture 82 having connecting pipe 84 fluidly communicating with an upper portion of container 70.
Detergent container 116 may be temporarily placed on the upper rack 120 with a fill tube 118 placed into aperture 82 allowing transfer of its contents into container 70. As will be described later in this specification, aperture cap 86 is of a design to engage aperture 82 for sealing of connecting pipe 84, yet providing a means for a moisture rich environment to be maintained in container 70 to prevent thickening of the detergent. FIG. 4 is identical to FIG. 3 with the exception of pictorial illustration of a flexible dispenser 122. This allows a cost savings to the homeowner by elimination of a heavy detergent container 116 as the flexible dispenser 122 is used only for a quick transfer, not storage, of the detergent into the container 70 before disposal.
Now referring to FIG. 5, set forth is a variation of the integrated storage container having three electrodes indicating either empty 90, 1/2 full 92 and full 94 fluid levels. As with the previous embodiments, transfer tube 74 is coupled to transfer pump 76 which engages dispensing tube 78 for subsequent insertion through the side wall of the dishwasher.
Now referring to FIG. 6, container 200 is illustrated beneath dishwasher 104 having fill port 202 positioned along dishwasher chamber floor 124 wherein the previously described mechanical visual indicator 204 threadingly engages opening 206 of the fill port 202. Visual indicator 204 includes a floating mechanism 208 placed along twist rod 210 providing a rotational movement to an indicator in relation to the amount of rod twist. As with the previous embodiment, liquid detergent is transferred via suction tube 212 coupled to transfer pump 214 for delivering fluid through tube 216 and into the dishwasher chamber 114 via dispensing mechanism 218. Vent 220 is located along the upper portion of container 200 allowing the visual indicator 204 to tightly seal the container to prevent water from entering the fill port during the dishwasher cycle. In this manner, liquid detergent is delivered through fill tube 118 into the opening 206. Low level determination is performed by sensing mechanism 224 which operates along the previously described principles of a sensing electrode.
FIGS. 7 through 9, set forth the aperture cap 86, as previously described, which is used for coupling to aperture 82 having connecting pipe 84 secured to a storage container located beneath the dishwasher chamber. The aperture cap 86 includes a plurality of venting holes 230 positioned on an outer surface 232 of the cap with a raised ridge 234 allowing for ease of twisting the cap for insertion and removal. Flexible gasket 236 prevents misplacement of the cap while opened. The cap has inner coupling tabs 238 which fit within slot 240 with a twist lock section 242 for securing the cap in position. It is noted that the gasket 236 forms around the inner surface of the cap for sealing against wall member 243. As noted in FIG. 9, aperture cap 86 shown in a sealed position wherein gasket 236 provides a seal with excess moisture drained by sloping surface 248 through aforementioned venting holes 230. A venting check valve is formed by flexible member 250 positioned along a rear portion of aperture cap 86 having a plurality of venting holes 252 which allows a small amount of moisture to bleed into connecting pipe 84 to help maintain a high moisture level thereby preventing thickening of the liquid detergent.
Now referring to FIGS. 10 through 13, set forth is the liquid injection dispenser member 275 mounted on a side wall 270 of a dishwasher having an inner lip 272 and an outer lip 274 engaging the dishwasher side wall 270 therebetween. Tube 276 is secured to the liquid injection dispenser member 275 by a coupling mechanism 278. As shown in FIG. 10, the liquid injection dispenser member 275 is in a closed position with cap 280 set in position by placement against cap seat 281 of inner lip 272. In FIG. 11, cap 280 of liquid injection dispenser member 275 is opened, the distance allowing the dispensing of detergent 282 to enter into the dishwasher chamber. Cap 280, as further illustrated by FIG. 12 is removable from chamber 284 allowing ease of cleaning or replacement if required. The cap 280 and spring 290 are housed in insertion fitting 286 and are held in place by a compression fit between a raised groove 289 on insertion fitting 286 and a recessed groove 291 on chamber 284. A plurality of raised ridges 288 along the surface of the insertion fitting 286 eases the removal and replacement thereof. Spring 290 is located within the cap 280 causing the cap to be drawn to a tight seal against cap seat 281 when no fluid is being dispensed through tube 276. It is noted that while dispensing of liquid detergent is taking place, it is performed during a cycle wherein the inlet solenoid is allowing water into the dishwasher chamber, thereby the displacement of the cap 280 allows for continually rinsing of the dispensing mechanism while detergent is being delivered and, after the deliverance, the washing water provides a removal of detergent from surfaces of cap 280 and cap seat 281 so as to eliminate the sticking of cap 280 upon closure.
Referring to FIGS. 14 and 15, set forth is yet another embodiment of a liquid dispenser member having an elbow 300 with a float ball 302 placed within floatable cage 304 which allows detergent to carry through dispensing tube 306 forcing float ball 302 upward until the deliverance of detergent stops float ball 302 is resituated to prevent water from entering elbow 300. It should be noted that a small amount of water entering elbow 300 is deemed beneficial as it provides additional moisture to the storage container which helps to prevent solidification of the detergent. As shown in FIG. 15, the elbow 300 can be easily removed for repair, cleaning, or replacement wherein housing 312 is operatively associated with inlet section 314 having locking tabs 316 which engage locking slots 318 of housing 312.
Now referring to FIGS. 16 through 18, the vent 220 includes a plurality of openings 320 which allow air to be drawn into the housing. Spring 322 is forced into a closed position by suction caused upon the transfer of liquid from the vented container. When sufficient air has displaced liquid within the vented container, openings 320 are disjoined from chamber 324 by the upward movement of chamber 324 providing a check valve type operation to inhibit additional air from entering the container.
As shown in FIG. 19, a pictorial of a dishwasher 350 having the controls integrated directly into the control panel is shown and made possible by the second embodiment of this invention wherein the homeowner may depress a light 352, normal 354, or extra heavy setting 356, as dependent upon the types of eating utensils to be washed, and hardness of water supply. As noted, next to each section is an illustration of the need for a light amount of detergent for china versus an extra heavy amount of detergent which is used for pots and pans. A systems monitor 360 is provided which allows a reading of the amount of detergent within the container providing a graphic illustration of a low, medium, or full amount of detergent.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown in the drawings and described in the specification. | The instant invention is an automatic detergent dispenser for residential dishwashers allowing transfer of liquid from a store purchased container or an integrated storage receptacle. The invention allows an individual to determine the amount of detergent to be transferred with provisions to operate the detergent transfer only upon demand preventing operation of the dishwasher if an insufficient amount of detergent is available. An alternative embodiment allows positioning of a storage container beneath the dishwasher chamber with provisions to fill the container. | 0 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the priority of German Patent Application, Serial No. 10 2007 019 590.9, filed Apr. 24, 2007, pursuant to 35 U.S.C. 119(a)-(d), the content of which is incorporated herein by reference in its entirety as if fully set forth herein.
BACKGROUND OF THE INVENTION
The present invention relates to a method of making a subframe of a motor vehicle, and to a subframe for a motor vehicle.
Nothing in the following discussion of the state of the art is to be construed as an admission of prior art.
Contemporary motor vehicles have subframes to receive components of the chassis and/or drive unit of the motor vehicle. Subframes are thus also part of the vehicle axle and stiffen the front structure and/or the rear structure. Therefore, subframes are firmly secured to the body of the passenger vehicle.
Stiffness of a subframe is crucial because it is subject to high static and dynamic forces during normal travel. As a result, subframes are complex components which must meet increasingly more stringent standards. On one hand, the deformation behavior must be optimized in the event of a crash, and yet the subframe should be lightweight and at the same time rigid and torsionally stiff.
To address the complexity issue of the geometry in the area of the attachment points, cast nodes of aluminum have been provided in the area of the axle and connected via profile elements made in particular as extruded intermediate pieces. This approach is very expensive in view of the exclusive use of aluminum. Moreover, the need for a welding joint to connect the cast nodes with the extruded profile is problematic in view of the different alloy composition and the substantial difference in the geometry. As hollow and thus lightweight castings are difficult to make and thus expensive, ribbed open structures are used. Such ribbed structures exhibit, however, inadequate torsion stiffness when compared to closed steel pipe or shell structures, especially when correlating the torsion stiffness to the mass of the profile element.
Other shortcomings of aluminum include the small modulus of elasticity of aluminum which translates to a reduced stiffness in particular when small-volume structures are involved. The size of a structure cannot fall below a certain minimum level, despite the tight space available. To still realize the necessary stiffness, extruded profiles would have to be made thicker. This, however, is not an economically viable solution. On the other hand, the outer dimensions of the profile elements cannot be increased in view of space limitations. Ribbed cast nodes thus are inadequate to have the desired torsion stiffness.
It would therefore be desirable and advantageous to address this problem and to obviate other prior art shortcomings.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, a method of making a subframe of a motor vehicle includes the steps of placing profile elements made of hollow sections of steel in a casting tool, and filling aluminum material into the casting tool to cast around the profile elements so as to form plural cast nodes on the profile elements in spaced-apart relationship.
The present invention resolves prior art problems by placing the profile elements of steel in a casting tool in which a cast node of aluminum is formed around each of the profile elements. A material union of aluminum and steel is normally very difficult to realize and requires particular welding processes, such as pressure welding, which are unsuitable for making complex structures, as is the case here. The present invention addresses this problem by employing an original forming process in order to create a subframe of a hybrid aluminum-steel composition. The supporting and connecting structure between the individual cast nodes involves the use of profile elements which are made of steel material, in particular a steel pipe frame, which is embraced at least in some areas by an aluminum sheathing which assumes the complex surface configuration and complex attachment function. The profile elements extend hereby through the cast nodes which thus become hollow.
According to another feature of the present invention, the profile elements may be joined in the casting tool to form an open or closed frame. In other words, the frame forms a ring or two (open) ends. The hollow section for making the profile elements of the frame may be a circumferentially closed hollow section with thin-walled cross section. The frame may either be made from a long hollow section that has been bent several times to establish several portions that represent the profile elements, or from several separate profile elements which are joined to form the frame.
Such a hybrid subframe is lightweight as the cast nodes are hollow as a result of the disposition of the steel pipe frame inside the cast nodes. The stiffness, in particular the torsion stiffness is increased in absolute terms but also in relation to the overall weight of the subframe. Material costs are low since the proportion of aluminum is decreased compared to a subframe made entirely of aluminum. Unlike an extruded part, the shape of a profile element or frame of steel pipe can be modified in many ways along its length. In other words, the profile element or frame may be formed or joined with different cross sectional zones. The forming process may involve an internal high-pressure forming process or a compression molding process.
The union between the cast node and the profile element or frame can be realized in a form-fitting manner or force-locking manner. In view of the greater temperature shrinkage of aluminum, the aluminum cast node is drawn tightly from outside against the inner profile element, thereby realizing a press fit. This press fit is superimposed by a form fit between the profile element and the cast node. Of course, additional formfitting measures may, optionally, be provided on a profile element or frame. The form fit can be enhanced by forming formfitting elements at least in length portions which are then subjected to the casting process. The term “formfitting element” relates hereby to modifications of the cross section in length direction. Examples include embossments or protrusions in which liquid aluminum can flow during the casting process.
According to another feature of the present invention, the profile element or the frame may be bent, and the cast nodes are being cast in an area of the bending zones around the profile elements to enhance the form fit. The presence of cast nodes alone in the area of the bending zones prevents any shift in length direction of the cast node in relation to the profile element or frame. Likewise, the cast nodes are prevented from pivoting about the length axis of the profile element or frame.
According to another feature of the present invention, a holding element of steel may be secured, e.g. welded, to a profile element or frame before or after the casting process.
The subframe may be made of one part or of several parts so that complex and lightweight structures can be created, even when using a steel pipe.
According to another aspect of the present invention, a subframe for a motor vehicle includes a plurality of profile elements, each profile element made of a hollow section of steel, and a plurality of cast nodes made of aluminum material and connected to the profile element in spaced-apart relationship through casting around the profile elements.
After manufacturing a steel pipe frame or part thereof, i.e. a profile element, through bending, joining, hydroforming, and/or compression molding in the desired combination, the frame and/or part is placed in the casting tool which has appropriate recesses for receiving the frame or profile element or parts of the frame or profile element in order to form the cast nodes. This is followed by the casting process, whereby the cast nodes can be cast sequentially, i.e. individually, or combined in groups, or simultaneously. The steel-aluminum composite parts can then be joined to form a subframe after the casting process. As an alternative, the composite structure may form the subframe which can then be transferred for further processing.
Based on metallographic results before and after a corrosion resistance test (VDA Wechseltest, VDA 621-415) and based on solid analysis in ejection and torsion tests, hollow sections of steel St35 in combination with pre and post treatments appear to be most suitable for casting. Pretreatment of profile elements before casting may involve a combination of surface blasting followed by degreasing with subsequent optional preheating. Post treatment of cast nodes after casting involves sealing of transition zones between the profile element and the aluminum cast node and subsequent cathodic electrodeposition and results in good corrosion characteristics.
The transition between steel and aluminum can be sealed by using a 1-component heat hardening sealing material on epoxy/polyurethane basis. After applying cold sealing material, exposure to air moisture or temperature causes pre-hardening. The finished product exhibits good wash-out resistance after pre-hardening, suitability for sealing different metals (e.g. steel, aluminum) as well as powder coating capability and cathodic electrodeposition capability. When the system is exposed to air moisture at room temperature, a thin skin is formed on the surface which protects the sealing material from being washed out. Final hardening is realized through temperature impact, e.g. in a cathodic electrodeposition furnace. Infrared and induction facilities are also applicable for final hardening.
The process sequence in low-pressure sand casting can be divided into eight process steps:
1. Preparation/Separation
In the first process step, the profile element is prepared. This involves in particular a cuffing of the profile element to size. Of course, profile elements may already been delivered with the required length so that this process step may also be omitted.
2. Forming
Next, the profile element is formed to receive its final shape. Bending methods are applicable here in particular. When complex geometries are involved, methods assisted by active agents may be used, such as an internal high-pressure forming process. Additional form-fitting elements, like embossments for example, may be provided in the later connection zone as the profile elements are formed.
3 Pretreatment
Next, the profile elements are liberated from surface oxides and contaminants at least or exclusively in those regions that are to be cast later through a blasting process. In addition, the surface is roughened by the blasts. Subsequently, it is suitable to have the profile elements undergo a cleaning process in a degreasing bath.
4. Casting Preparation
Immediately before being subjected to low pressure casting in sand, the profile elements are heated in the region to be cast. Tests have shown a beneficial temperature in a range from 380° C. to 420° C., especially 400° C. Heating may be realized with hot air or inductive heating. Inductive heating has the benefit that the inductor geometry can be suited to heat only the area of the profile element which is intended for being cast. Risk of heat distortion is minimized in neighboring areas of the profile elements. In other words, the profile element can be heated to the desired temperature either in its entirety or only in those areas that are being cast. As induction heating has a high heat-up rate, it is possible to quickly heat the profile element. For example, a pipe having an outer diameter of 35 mm can be heated in 6 seconds along a length of 150 mm from 20° C. to 400° C.
5. Casting
When low pressure casting in sand is involved, the profile element is placed immediately after the heating process into a sand mold and cast around to prevent cooling. When large scale production is involved, other casting processes may also be envisioned, like, e.g., die casting. Die casting may not require a complete or partial heating of the profile element. Use of galvanized profile elements may in some instances also eliminate the need for cathodic electrodeposition.
6. Separation
Following the casting process, the functional areas of the subframe provided with cast nodes is machined through material removing processes. Examples include drilling or milling operations.
7. Sealing
Next, a sealing mass is applied in the transition between profile element and cast node of aluminum. A robot-assisted application unit may hereby be utilized.
8. Coating
After being applied, the sealing mass has to pre-harden, for example over a time period of 4 hours at a temperature of about 23° C. Following pre-hardening is cathodic electrodeposition for producing the subframe as finished product.
Handling of the components of the subframe between the processing steps can be executed with the assistance of robots. This maximizes reproducibility of the processes and same quality. The present invention thus enables the application of a low pressure sand casting process to reliably connect aluminum cast nodes with a steel pipe frame in order to produce a subframe for receiving components of the chassis and/or drive of a motor vehicle.
In basic tests, model nodes were produced in a low pressure sand casting process and various pipe materials (St35 and 1.4301) with different surfaces were examined during casting tests.
The metallographic tests show that pre-treatment of uncoated hollow sections effectively prevents the presence of shrinkage in the casting. Pre-treatment involves blasting of the pipe surface with the abrasive “AFESIKOS” marketed by Asikos Strahimittel GmbH, Germany. This abrasive involves a synthetic mineral which is free of iron according to ISO 11126, i.e. an aluminum silicate melt with a specific weight of 2.6 g/cm 3 . Grain size ranges from 0.2 to 0.5 mm at 2 bar impingement pressure. Cleaning is followed by degreasing with acetone and subsequent pre-heating of the profile elements to a temperature of 400° C. The examination of coated profile elements in the form of pipes (St35 hot-galvanized, St35 hot galvanized and heat-treated, St35 electrogalvanized) has shown increasing shrinkage and cracking which could not entirely be reduced with pre-treatment. The presence of a new intermediate layer with good adhesiveness could be shown in hot galvanized profile elements of St35 after casting in the transition zone between aluminium and steel.
Pretreatment In pipes made of materials St53 and 1,4301 resulted in good flow of melt. Ageing tests have shown that hollow sections of St35 have good corrosion results due to the combination of sealing and cathodic electrodeposition. Penetration of moisture into the connection zone between hollow section and cast nodes could be prevented.
Ejection experiments have shown that highest strength of up to 60 kN have been achieved for hot galvanized pipes. This can be attributed to the presence of the intermediate layer which forms on the pipe during casting. Uncoated pipes of St35 showed a much greater influence of the test temperature upon the strength of the connection as a consequence of the different coefficient of thermal expansion between steel and aluminum. It has been shown that the connection strength decreases as the temperature increases. Ageing did not influence the breakaway force in the ejection experiment of cast and subsequently sealed St35 pipes. Without heat treating aluminum after casting, higher breakaway forces have been noted and a greater migration of aluminum particles on the pipe surface have been observed. The connection strength is similarly affected when the pipe surface is exposed to blasting. When surfaces of pipe material St35 were exposed to a blasting process, the breakaway forces are higher and aluminum particles migrated to a greater extent in the ejection process compared to pipes that are not subjected to blasting. The pipe material also impacts the breakaway forces in the ejection experiment. In St35 pipes with blasted surface and heat treatment, breakaway forces of 30 kN were determined. In pipes of 1.4301 and same parameters, the breakaway forces were 14 kN and thus significantly lower. This can possibly be attributed to the fact that blasting of the pipe surfaces causes different steel materials to have different surface structure and thus different magnitudes of breakaway forces.
Torsion experiments also showed different breakaway forces for pipe materials St35 (1.4 kN) and 1.4301 (0.9 kN) in cast nodes with an overlap of a length of 45 mm. Furthermore, tests with cast pipes of St35 also showed that the correlation between overlap length and breakaway moment is non-linear. In addition, pipes of St35 showed after being cyclically damaged that the connection strengths in the torsion experiment decreases.
It is expected that higher cool-down rates and higher casting pressure in the die casting process render casting of coated hollow profiles less problematic than when low pressure sand casting is involved. In some instances, a change of the casting process may also simplify the pretreatment of the pipes, i.e. pre-heating and blasting in particular may be omitted.
BRIEF DESCRIPTION OF THE DRAWING
Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
FIG. 1 is an isometric illustration of one embodiment of a subframe according to the present invention for use in a motor vehicle, in closed configuration;
FIG. 2 is an isometric illustration of another embodiment of a subframe according to the present invention for use in a motor vehicle, in open configuration;
FIG. 3 is an isometric illustration of the subframe of FIG. 1 which has been cut open;
FIG. 4 is a detailed cutaway view, on an enlarged scale of the subframe of FIG. 1 ; and
FIG. 5 is a perspective cutaway view of a profile element with a formfitting element in a length portion thereof.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Throughout all the figures, same or corresponding elements may generally be indicated by same reference numerals. These depicted embodiments are to be understood as illustrative of the invention and not as limiting in any way. It should also be understood that the figures are not necessarily to scale and that the embodiments are sometimes illustrated by graphic symbols, phantom lines, diagrammatic representations and fragmentary views. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted.
Turning now to the drawing, and in particular to FIG. 1 , there is shown an isometric illustration of one embodiment of a subframe, also called chassis frame, in accordance with the present invention, generally designated by reference numeral 1 , for use in a motor vehicle such as a passenger car. The subframe 1 has four cast nodes 2 , 3 , 4 , 5 , which are respectively arranged in corner zones of the subframe 1 , and profile elements 6 , 7 , 8 , 9 which extend between the respective cast nodes 2 , 3 , 4 , 5 . The subframe 1 shown in FIG. 1 has a closed configuration to form a closed frame 12 .
FIG. 2 shows an isometric illustration of another embodiment of a subframe according to the present invention, generally designated by reference numeral 1 a , for use in a motor vehicle. Parts corresponding with those in FIG. 1 are denoted by identical reference numerals and not explained again. The description below will center on the differences between the embodiments. In this embodiment, the subframe 1 a has an open configuration. This can be achieved, e.g. by cutting the profile element 7 in FIG. 1 to expose ends 10 , 11 of a frame 13 in spaced-apart relationship. FIG. 2 shows that the individual profile elements 6 , 7 , 8 , 9 are formed from a hollow section which may be a circumferentially closed thin-walled steel pipe to form the supporting frames 12 or 13 of the subframe 1 or 1 a , respectively.
In the non-limiting exemplified embodiments, shown in FIGS. 1 and 2 , the individual profile elements 6 , 7 , 8 , 9 are not separately connected with the individual cast nodes 2 , 3 , 4 , 5 , since the frame 12 , 13 is a continuous structure which also passes through the cast nodes 2 , 3 , 4 , 5 . The cast nodes 2 , 3 , 4 , 5 are cast by an original forming process externally about the frame 12 , 13 , as shown in FIGS. 3 and 4 which illustrate broken-up views of the subframe 1 . The material of the cast nodes 2 , 3 , 4 , 5 is provided solely on the outside of the frame 12 . In other words, the cast nodes 2 , 3 , 4 , 5 are hollow on the inside.
The form fit between the cast nodes 2 , 3 , 4 , 5 and the frame 12 , 13 is realized, i.a., by bending the frame 12 , 13 . In other words, the cast nodes 2 , 3 , 4 , 5 are arranged in the bent corner zones of the frame 12 , 13 so as to embrace the frame 12 , 13 in the form of a sleeve. In this way, the cast nodes 2 , 3 , 4 , 5 are prevented from shifting in length direction as well as from pivoting about the length axis of the frame 12 , 13 .
FIGS. 3 and 4 also show that the cast nodes 2 , 3 , 4 , 5 have walls that are significantly thicker than the thin-walled steel pipe which is embedded in a formfitting manner in midsection of the cast nodes 2 , 3 , 4 , 5 .
Referring now to FIG. 5 , there is shown a perspective cutaway view of a profile element 6 , 7 , 8 , 9 with a formfitting element in the form of an embossment 14 in a length portion thereof. The term “formfitting element” is to be understood as relating to any modification of the cross section in length direction. Another example involves protrusions in which liquid aluminum can flow during the casting process.
Although not shown in detail, a holding element of steel may be secured, e.g. welded, to a profile element 6 , 7 , 8 , 9 or frame before or after the casting process. An example of a holding element includes weld-on elements for securement of cables, pipe elements, mounts or exhaust components.
While the invention has been illustrated and described in connection with currently preferred embodiments shown and described in detail, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. | In a method of making a subframe of a motor vehicle profile elements made of hollow sections of steel are placed in a casting tool. Subsequently, aluminum material is filled into the casting tool to casting around the profile elements so as to form plural cast nodes on the profile elements in spaced-apart relationship. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a device for fastening an object to a wall, or the like, as a plug-in mounting, including an externally threaded mounting bolt one end of which is formed into a partial cone whose maximum diameter at most is equal to the diameter of the remainder of the bolt body, and the other end of which is threaded.
Such fastening devices which are also described as so-called externally threaded pegs or tie bolts, are pushed into a hole in a wall or the like of concrete, masonry or the like and there secured, the hole having substantially the same diameter as the holes provided in the object to be fastened.
Fastening devices which consist of dowels or wood screws are different in that the screw diameter corresponds to the diameter of the hole in the object to be fastened, while the hole in the wall for the dowel is of larger diameter. In this case, an expander element is provided for fastening the externally threaded peg into the hole. In its frontal position the peg can be driven, with the bolt, into the hole and then expanded so that the taper of the bolt will be moved through by axial displacement.
A fastening device of the kind disclosed in U.S. Pat. No. 3,766,819 has half-shell expander element parts of like form, but when assembled with the bolt at the operating site at which the fastening device is assembled, are appropriately sorted out, that is to say brought into the correct position and orientation. This is, however, very difficult because they are not easy to dispose of in this way and the operation has to be carried out by hand.
OBJECT AND SUMMARY OF THE INVENTION
It is an object of the present invention therefore to provide a fastening device of the kind set forth in which the two parts of the expander device, which are each of half-shell form, can be fed in and mounted on the externally threaded mounting bolt mechanically.
This object is achieved by the present invention by the provision of an expander element which is transversely symmetrical and, when viewed in development, is point symmetrical. The expander element is mounted on the mounting bolt in a radially form-locking manner.
In the fastening device according to the present invention, therefore, the parts of the expander device are preformed and hardened in accordance with their status in the assembled condition. Since they are point-symmetrical, they are all of the same construction and can be introduced onto the outer threaded mounting bolt in the final assembly with either end leading. This makes it possible for the parts of the expander element to be sorted or assembled automatically, that is to say mechanically. The lobes provided on the parts of the expander element on the one hand have the effect that the parts cannot shift axially relatively to one another, so that their position always remains uniform relatively to the taper, and on the other hand, as a result of their profiling, have the effect that these two parts constituting the expander elements are held in the radial direction against parting. This form-locking connection, possibly with play, in the radial direction is either produced by the fact that the two parts snap into one another, the lobes being slightly elastically deformable in the axial direction, or by the fact that when the two parts are laid on the bolt the end lobes are slightly plastically deformed in the axial direction so that the adjacent lobes engage one in the other.
In other preferred embodiments of the present invention the lobes are of differing radius at the plane of separation in the expander element so that some of the lobes in the assembled condition overlap the outer diameter of the externally threaded bolt and thereby deform barb-like edge portions which, at the commencement of the pull-out movement of the threaded bolt hold the expander element in the fastening hole concerned. These barb-like edge portions can be made very simply in the manufacture of the parts of the expander element in a single operation with the bending of sheet which has been stamped out.
Further details and forms of the invention are to be found in the following description in which the invention will be described and explained in relation to the exemplary embodiments thereof which are illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a fastening device in the assembled condition in accordance with one embodiment of the present invention;
FIG. 2 is a plan view of an expander element shown developed, but before the form-locking connection of the two parts of the expander element in accordance with an embodiment of the present invention;
FIG. 3 is a section on the line III--III of FIG. 1, but the parts being shown in the condition they assume during the imposition of the parts of the expander element on the part, the finally assembled condition being indicated in dotted lines;
FIGS. 4a and 4b are plan views of the element respectively before and after the assembly in accordance with another embodiment of the present invention;
FIG. 5 is a section similar to that of FIG. 3 but illustrating a further embodiment; and
FIGS. 6a and 6b are plan views corresponding to FIGS. 4a and 4b and related to the embodiment of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The fastening device, or externally threaded plug or tie bolt 11 according to the invention is used to secure objects by so-called plug-in mountings on a wall, to a roof or the like of concrete, masonry or the like. The expression "plug-in mounting" is used to refer to the fact that the device 11 is pushed, or driven in through the object placed against the wall or the like and is then tightened. Since the attachment hole in the wall is approximately the same diameter as the fastening holes in the object to be fastened, the device 11 can be used as a template for indicating and forming of the fastening holes.
The externally threaded fastening device, plug or tie bolt 11 comprises essentially an externally threaded mounting bolt 12, a nut 13 and an expander element 14. The nut 13 which is used to tighten the inserted threaded bolt 12, which is threaded on an outer threaded part 16, with the insertion of a support washer or shim 17; and when the threaded bolt 12 is inserted, is generally tightened to such an extent that a marker ring 18 of the threaded part 16 is seen. Adjoining the threaded part 16 is a shank 19 of the bolt which at its rear or inner end merges into a cylindrical section 21 of smaller diameter. The cylindrical section 21 receives the expander element 14 and is of a length which is approximately the width of the element 14. Adjoining this cylindrical section 21 is the small diameter end of a cone 22 which merges into a cylindrical end 23 with a diameter equal to that of the shank 19.
The expander element 14 comprises two identical substantial half-shell parts 26, 26' or 26" which are of such form and are so attached to the outer externally threaded bolt 12 that in the first place they cannot be displaced axially relative to one another, and they hold together on the bolt in a form-locking manner and against displacement in the radial direction, that is to say they are secure against radial separation.
As can be seen particularly from FIGS. 2, 4 and 6 each expander element part 26, 26', 26" is punched from a flat metal sheet to give it a basically rectangular shape with two lobes 27, 27' and 27" and 28, 28', and 28" at the longitudinal sides thereof. The end lobes 27, 27' and 27" and the central lobes 28, 28', and 28" are formed or punched out at the two longitudinal sides in such a way that the parts 26, 26', 26" are of point-symmetrical form as seen in the developed views, which means that each expander element part 26, 26', 26" in relation to its lobes can have only one position, that is to say is always correctly positioned. Each expander element part 26, 26', 26" is also transversely symmetrical (see FIGS. 3 and 5). The parts 26, 26', 26" are bent from the flat condition into a cylindrical half-shell form as can be seen in the views given in FIGS. 3 and 5. The central body part 29 of the parts 26, 26', 26" which does not make a complete half shell is provided with an internal radius corresponding to the outer radius of the cylindrical area 21 of the bolt 12. The lobes 27, 27', 27" and 28, 28', 28" overlap at the plane of separation 31 of the element 14 shown in FIGS. 3 and 5 in such a manner that they are approximately halved in length by this plane.
In the embodiment illustrated in FIG. 3 the half shells 26, 26' can be positioned directly on the cylindrical area of the bolt 12 because the lobes 27, 27', 28, 28', at least at the end overlapping the plane 31, are of larger radius. It is apparent from FIG. 3 that the lobes 27 extending from the body part 29 of the half shell part 26 extend to some extent beyond the plane 31 in a straight line and therefore have an inner spacing of the same order as the inner diameter. In contrast, the central lobes 28 have their root tangentially disposed at the longitudinal side of the half shell part 26 or the shank 19, and likewise extend rectilinearly so that they protrude externally, which means that their outer edge overlaps the outer diameter of the completed expander element 14 substantially more than do the end lobes 27. In the assembled device 11 the result is to provide barb-like edge portions 42 which at the commencement of the tightening or fastening operation movement hold the bolt 11 in the bored hole. From FIG. 3, and in connection with the lower part 26, the extent to which the lobes 27 and particularly the lobes 28 project beyond the joint between the cylindrical zone 21 and the shank 19 and thus the outer diameter of the bolt 12 can be seen. This also applies to the lobes 27' and 28' of the part 26'.
The same applies to the embodiment of FIG. 5. In this embodiment, however, the outer lobes 27" follow the radius, while the inner lobes 28" extend tangentially from the plane of separation 31.
Here also there are barb-like edge portions 42. In addition, the parts 26" of the expander element 14 overlap the cylindrical zone 21 of the bolt 12 so as to be radially snapped thereon and hold the elements against separation. It will be understood that in both cases (FIGS. 3 and 5) the other lobes in each case will be correspondingly formed.
FIG. 2 illustrates, as a first example, the parts 26 of the expander element 14. According to this illustration, each part 26 is so formed initially, that is to say before being placed on the bolt 12, that the outer edge of the end lobes 27 extend outwardly from the end surface 32 of the body part 29, by the formation of a projection 33. The rear of the lobe 27 is rounded as is the adjoining rear of the central lobe 28 of this same part 26. This central lobe 28 is provided towards the end surface 32 of the body part 29 with a trough 37 forming a peak projection 36. This trough extends substantially perpendicularly into the end surface 32. The trough 37 is of such form that the rear of the end lobe 27 fits thereinto to form a form-locking connection. The section between each end lobe 27 and each central lobe 28 is intended and shaped for connecting the central lobe 28 of the other half shell part 26 therewith. As can be seen from FIGS. 2 and 3, two half shell parts 26 forming an expander element 14 are disposed and pushed into engagement with one another on the cylindrical zone 21 of the bolt 12 in such a way as to form the connection illustrated in the developed view in FIG. 2, which at first only holds firmly in the axial direction. The insertion of the lobes 27 and 28 is effected without resistance. In this condition, the two parts 26 are relative to one another in the axial direction but do not exhibit a form-locking connection in the radial direction, so that they could still be separated (fall apart). To provide radial security against such an event, a tool indicated at 38 is applied in the direction as shown by arrow A. The shoulder 24 at the transition between the cylindrical zone 21 and the shank 19 of the bolt 12 serves as a counter resistance. As a result, the end lobes 27 are deformed into the troughs 37 so as to produce the arrangement illustrated in FIG. 1 in which the leading edges of the end lobes 27 are substantially coplanar with the end surface 32 of the body part 29. Even if, in view of the hardening of the half-shell part 26, only an incomplete deformation takes place on account of the elasticity which is still then present, the lobes 27 and 28 mutually interengage to such an extent that the parts 26 are not able to fall apart under their own weight, that is to say the form-locking connection can also have considerable amount of play. The deformation itself will be promoted: in the first place by the fact that the tool 38 and the support 24 bear against a narrow annular surface formed by the projection 33; in the second place by the fact that the end lobes 27 have a constriction 39 in the zone where they adjoin the body part 29 which forms a pivot for the deformation; and in the third place in that the peak projections 36 of the central lobes 28 press or are applied against this constriction 39.
In the second embodiment of the present invention illustrated in FIGS. 4a and 4b the parts 26' of the expander element 14 are so formed that there is no deformation of the end lobes 27' during the assembly on the bolt 12. Rather, a clip, or snap interconnection in the axial direction between the lobes 27' and 28' provides the radial hold against separation of the expander element 14. The difference between this embodiment and the embodiment previously described is primarily only the form of the end lobes 27'. The outer edges of the lobes 27' are formed ready for assembly and aligned with the end surface 32 of the body part 29. In addition, the peak projection of the lobe 28' can be formed as a rounded projection 36' for considerably better slidability.
The starting condition is illustrated in FIG. 4a prior to the two expander element parts 26' being snapped into one another. As can be seen from the figure, the rounded projection 36' of the central lobe 28' will bear against the back of the end lobe 27'. In view of the hardness of the part 26' and the constriction 39 of the end lobe 27', and to some extent also of the central lobe 28' the lobes will yield resiliently so that the two parts 26', after overcoming a certain amount of counter pressure, can be snapped into one another to produce the connection illustrated in FIG. 4b. The lobes 27' and 28' can be so shaped that in the assembled and mounted condition of FIG. 4b there is a greater amount of play because, generally speaking, only a very small form-locking connection will radially hold the parts 26' sufficiently.
In the third embodiment of the invention illustrated in FIGS. 5, 6a and 6b, the expander element parts 26" are formed such that when mounted on the bolt 12 they both hold one another in position and also on the cylindrical zone 21 of the bolt. This latter effect, as mentioned, results from the fact that the outer lobes 27" when slipped onto the zone 21 of the bolt are elastically enlarged in the radial direction. The first effect is achieved by the special construction of the inner surfaces or edges of the lobes 27" and 28" so that they coincide with the generating of the cylindrical zone 21. Whilst the outer edges of the lobes 27", in each case, constitute an extension of the rectilinear end surfaces 32 of the part 26", the inner lateral edges 43 which are not parallel to the longitudinal axis of the parts 26" are arranged at an acute angle to the end surfaces 32 or to the transverse medial plane. The individual edges 43 of the lobes 27" and 28" which interengage or lay side-by-side are parallel to one another. Whilst the inner lobes 28" are somewhat of parallelogram form, albeit with rounded corners, the outer lobes 27" are of somewhat club-like, that is to say they are thickened at their leading free ends.
The procedure for mounting the two parts 26" of the expander element on the cylindrical zone 21 of the bolt is seen in FIGS. 6a and 6b, in which only the longitudinal axis 46 of the threaded bolt 12 is shown. The two parts 26" of the expander element are placed on the cylindrical zone 21 from the two sides of the bolt so that their longitudinal axes are at an acute angle to one another, the open sides preferably being directed towards the cone 22. The opening angle of the two parts 26" is largely constituted by the acute angle which the inner edges 43 of the lobes 27" and 28" form with the transverse medial plane, because in the condition illustrated in FIG. 6a the extension of these inner edges 43 of the upper part 26" is perpendicular to the longitudinal axis of the lower part 26". The longitudinal axes of the two parts 26", however, do not run parallel in the plane of the drawing but intersect in this plane at an acute angle. Also, it is necessary for the inner lobe 28" of the upper part 26" to be able to engage in the righthand slot formed by the inner lobe 28" and outer lobe 27" of the lower part 26". If the two parts 26" are pressed together on the cylindrical zone 21 of the bolt, they first turn in the plane of the drawing and secondly in the direction of arrow A parallel to one another so that they will snap one into the other and assume the position shown in FIG. 6b.
As can be seen from this FIG. 6b, the opposed inner edges 43 of the two adjacent inner lobes 28" of the two parts 26" define between them a gap 44 which in effect facilitates, on the one hand, the form-locking interengagement of the parts 26", and on the other hand, also has a favorable effect on the permissible manufacturing tolerances. In the position illustrated in FIG. 6b the righthand end surfaces 32, in relation to this figure, are applied against the collar or shoulder 24 of the zone 19 of the bolt, while the inner end surfaces 32 (as related to FIG. 6b) bears against a part of the cone 22. This means that the two parts 26" of the expander element can not move in practice in the axial direction so that any radial parting of the two parts is no longer possible by virtue of the oblique edges 43. It will be understood that this interfitting, form-locking connection, effective in the radial direction can be achieved even in the absence of the form-locking snapping together of the two parts 26" over the zone 21 of the bolt, because the two parts 26" of the expander element are fixed in the axial direction between the cone 22 and the shoulder 24 with negligible play.
By reason of the point-symmetrical construction of the parts 26, 26', 26" of the expander element 14 and the simple form-locking engagement producing a radial holding of the parts, the mounting of the expander element 14 on the externally threaded bolt 12 can be carried out mechanically, that is to say automatically. The individual separator element parts 26, 26', 26" are of a nature that they are readily sorted, i.e., graded and orientated, because it is of no moment which end surface 32 is leading or trailing. Moreover, the final connection of the two parts 26, 26', 26" on the bolt 12 can take place by simple pressure in the axial direction for the deformation of the end lobes 27, or by simple pressure in the radial direction to produce the snap-in connection of the two parts 26' and 26" with one another or with the bolt.
As can be seen from FIG. 1, when the expander element is mounted over the cylindrical zone 21 of the bolt 12, the outer diameter of the expander element 14 can slightly overlap the outer diameter of the shank 19 in the zone of the body part 29. The hole 41 in which the externally threaded peg 11 is inserted has an internal diameter equal to the outer diameter of the shank 19. This means that the externally threaded peg 11 is driven into the hole 41 with the expander element 14 being pressed in and bearing against the shoulder 24 and, within the hole 41, particularly because of the barb-like edge portions 42, constituted by the projecting lobes 28, 28', 28", is therein clamped. The externally threaded peg 11 is driven in until the end 13 arranged at the beginning portion of the threaded section 16 bears against the edge of the object which is to be fastened in position. The nut is then turned so that the threaded bolt 12 is pulled out of the hole 41. Because of the initial clamping of the expander element 14 within the hole 41 it remains stationary so that the cone 22 of the bolt 12 slides into the expander element 14 and this is pressed radially outwards and affords an increase in the clamping effect. The bolt 12 is drawn out in this way until the marker ring 18 is visible, in which condition the expander element 14 is over the maximum diameter of the cone 22, i.e., has performed its maximum expansion. Since the parts 26 are held stationary in the axial direction against one another, the necessary firm hold is securely established. | The device for fastening an object to a wall or the like by a push-in mounting, comprises an externally threaded bolt, at one end of which a nut can be threadedly advanced, and on the other end which is at least partially conical and whose maximum diameter is at most equal to the diameter of the bolt, has displaceably mounted thereon an expander element composed of two half-shell like parts. The two parts of the expander element are provided at their longitudinal edges opposite to one another in the mounted condition with integral lobes disposed transversely symmetrical and, when viewed in development, point-symmetrical, in relation to one another. The edges of the lobes are formed in such a way as to provide, when disposed on the externally threaded bolt, a form-locking connection. | 5 |
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government for governmental purposes without the payment of any royalty thereon.
BACKGROUND OF THE INVENTION
This invention relates generally to an arrangement for preventing the pollution of a body of water having variable levels and more particularly to a buoy type oil gate which holds back pollutant products. Previously, oil spills into a stream of water having variable flow and, therefore, variable water levels, involved the use of high priced oil separators through which the flow of water was made to pass. In addition to expensive equipment costs required for an oil separator system, a requirement exists for much costly manpower and maintenance for effective operation. The high costs have inhibited adoption of ecological control systems because of the economic impact of high cost maintenance and equipment on the industries causing the pollution. My invention avoids the high costs attendant to prior art water pollutant control systems.
SUMMARY OF THE INVENTION
The invention relates to a buoy type oil gate which straddles a stream having variable water levels. The gate is arranged to float such that it has an area extended above the water level and has ends which ride in and seal to channels proximate to the banks of a stream.
Accordingly, it is a primary object of this invention to provide a buoy type oil gate which floats on the surface of a body of water and rides up and down within a pair of channels such that it has the capability of holding back oil from passing downstream of said gate.
It is another object of this invention to provide a buoy type gate having the gate portion of polyurethane coated timber.
It is still another object of this invention to provide a buoy type oil gate which rides in guide means located at the sides of a body of water having variable levels.
It is a further object of this invention to provide a series of buoy type oil gates for controlling the spread of petroleum and other floatable pollutants downstream of the location of the gates.
It is a still further object of this invention to provide a buoy type oil gate which is easy and economical to produce of standard, conventional, currently available materials that lend themselves to conventional manufacturing techniques.
Another object of this invention is to provide a passive control system for holding back pollutants in a stream without damming the stream.
These and other advantages, features and objects of the invention will become more apparent from the following description taken in connection with the illustrative embodiments in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross section across a creek or river bed illustrating the positioning of the parts forming the buoy type gate of this invention;
FIG. 2 is a pictorial representation of a channel and the gate member of this invention;
FIGS. 3 and 4 are alternative embodiments for the ends of the gate member; and
FIG. 5 is a schematic illustration of a series of gates which may be utilized for wider body of water.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the Figures there is shown a device for holding back contaminants which float upon a body of water and more particularly one which has variable levels due, for example, to the effects of rainy seasons, etc. In order to perform the invention as best illustrated in FIG. 1 a hole is excavated at 10 into the bank 12 of a brook or river and filled with fieldstone 14. At the builders option, cement or cemented fieldstone may be utilized. A channel 16 is placed at each side of the stream and abuts the fieldstone such that the channel now seals the water from going around the system of the invention. A coated timber 18 is placed across the body of water and is installed such that it floats thereon with a portion below the water level and a portion above. The timber gate is constrained by the engagement of the ends thereof with the channels 16. The channel members 16 may be of a conventional U-shaped construction or I-beam construction, as illustrated in FIG. 2, and would be driven into the ground or bed of the stream for a number of feet and would extend above the flood level of said stream.
The ends of the timber 18 are trimmed, as illustrated at 20 in FIG. 2, to fit loosely within a channel 16 of the I-beam. The corners are rounded or beveled as at 22 in order to minimize the amount of friction and to allow free movement of the timber to follow the level of the stream. The loose fit and beveling is to reduce the friction and allow for free movement with the stream thereby avoiding a seizing of the gate to the channel by pollutents or snow and ice. A polyurethane coating is applied to the timber to seal it and provide for extended life.
The height of the gate timber 18 should be sufficient to hold back pollutants and debris that might possibly be carried over the timber if they should impinge against it with any appreciable amount of momentum.
FIG. 3 illustrates an alternative embodiment of the end 20 of the timber 18. Here a wire 30 is applied to the end portion engaged by the channel 16. The wire is of the heating element type, for example, of nichrome, and is connected to a source 32 and a switch 34 in series therewith to allow for a closure of the circuit and a heating of the wire. This avoids a seizing of the timber in the channel by melting ice during the winter that would not allow the gate timber 18 to follow the level of the stream. The wire could also run lengthwise from end to end along the timber 18 in order to assure freedom of the entire gate from ice. The wire may be embedded in grooves 36 in the timber in order to avoid having them short circuit against the metal of the channel member 16.
The avoidance of seizing at channel 16 may also be controlled by means of a teflon coating 40 applied to the ends of the gate 18, as illustrated in FIG. 4, thereby minimizing friction and providing a surface to which ice does not readily adhere.
The invention thus far described can also be utilized for large spans for large bodies of water and would have the system illustrated in FIG. 5 applied thereto. In this instance a series of gates 18 are formed and connected to a number of I-beam type channels 16 to straddle the stream.
STATEMENT OF OPERATION
With the buoy type gate or gates, previously described, installed across a stream, the gate timber 18 would float on the water and the pressure of the stream flow would cause the timber to seal across the downstream portion of the interior of the channels 16. Pollutants such as oil or gasoline and other contaminants which float on water would be held back by the timber. The same type of operation would occur with multiple gates straddling a single stream. At intervals personnel would take a pump to skim the contaminants off the top of the water and keep the system in operation. Additional timbers 18 could be stacked to form a higher gate thereby cutting down on the frequency of pollutant removal. Also, in place of the vertical orientation illustrated the channels 16 could be tilted in a downstream direction in order to assure smooth operation of the system by minimizing frictional forces.
Although the invention has been described with reference to particular embodiments, it will be understood to those skilled in the art that the invention is capable of a variety of alternative embodiments within the spirit and scope of the appended claims. For example, the gate portion need not be of wood but may be of any material or construction that floats. | For use in a body of water having variable levels, means sealing channels to the banks of said body of water, and floatable means extending across said body of water and into said channels capable of holding back petroleum products and other floatable debris released upstream into said body of water. | 4 |
FIELD OF THE INVENTION
The invention pertains to a device for adjusting the cutting length of a chopping device.
BACKGROUND OF THE INVENTION
Field choppers employed in agriculture are used for cutting and picking up harvested crops, for example, grass or corn, which is normally used as fodder for cattle. To promote the digestibility of the fodder, the cut length of the harvested crop is very important. In current field choppers, means have therefore been proposed for adjusting the cutting length of the chopping device wherein hydraulic motors, adjustable either continuously or in steps or shifting transmissions have been used. The operator of the field chopper, however, must make the decision about the cutting length, and in this regard must employ his experience or take other factors into consideration. It is possible that poor cutting lengths will be selected, in particular in the case of inexperienced operators or under unsuitable conditions.
The problem underlying the invention is that of relieving the field chopper operator of the task of adjusting the cutting length.
SUMMARY OF THE INVENTION
According to the present invention, there is provided an improved arrangement for adjusting the cutting length of a chopping device.
An object of the invention is to provide an improved cutting length adjusting arrangement wherein a sensor is provided to ascertain one parameter of the crop to be harvested, and to adjust the cutting length of the chopping device as a function of the measured parameter. In one simple embodiment, the measurement value of the sensor, and/or of a cutting length derived from it, is displayed, and the operator will adjust the cutting length accordingly. In one preferred embodiment, the cutting length of the chopping device will be adjusted automatically to a value derived from the measurement value from the sensor.
In this manner an optimum digestibility will be obtained, regardless of the properties of the chopped crop. Thus, an optimum utilization of the nutritional value of the harvested crop will be obtained when it is used as animal fodder.
For example, the sensor can determine the moisture content of the chopped crop. As a moisture sensor, in particular a microwave sensor, a capacitive sensor, or a conductivity sensor can be used. However, any other kind of sensor suitable for moisture measurement can be used. If the chopped crop is relatively moist and thus more easily digested, then a greater cutting length would be adjusted than in the case of dry chopped material.
But instead of, or in addition to moisture, the nutrient content of the crop can be measured, for instance, as determined by an appropriate sensor, as disclosed for example in U.S. Pat. No. 5,991,025. Also, the grain content can be measured optically. Other constituents of the chopped crop can also be ascertained.
The cutting length can be adjusted by a suitable control device, which may be either separate or integrated into the existing onboard electronics systems. This is linked with the sensor and controls the cutting length according to its measurement value. The cutting length can be adjusted by changing the rotational speed of a chopping drum and/or by variation in the speed with which the harvested crop is delivered to the chopping drum. As a rule, the second variant will be used, wherein the rotational speed of the front press rollers will be varied by means of an electric motor or hydraulic motor. In this case, a portion of the drive power of the front press rollers can be employed mechanically. Basically, however, it would also be possible to vary the rotational speed of the chopper drum, which can be done by adjusting the rotational speed of the drive motor.
In a preferred embodiment, the control device is connected to a memory unit in which information concerning the cutting length and the rotational speed of the chopper drum and/or of the front press rollers is stored as a function of the measurement values of the sensor, e.g., in the form of a table, a database or mathematical curves or functions. This information can be derived from fodder tests or other sources.
BRIEF DESCRIPTION OF THE DRAWINGS
The figures show one embodiment of the invention, which is described in greater detail below.
FIG. 1 is a schematic, left side elevational view of a harvesting machine with which the present invention is particularly adapted for use.
FIG. 2 is a schematic illustration of the device for effecting automatic adjustment of the cutting length.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 , there is shown a harvesting machine 10 , illustrated as a type of self-propelled field chopper including a main frame 12 supported on front and rear wheels 14 and 16 . The harvesting machine 10 is operated from a driver's cab 18 , from which a harvested material pickup device 20 is visible. The crop, e.g., corn, grass or the like, picked up from the ground by the harvested material pickup device 20 , is moved through four front press rollers 30 , 32 , 34 , 36 to a chopper drum 22 , which chops the crop into small pieces and sends it to a conveyor unit 24 . The material passes from the harvesting machine 10 to a side trailer via a discharge chute 26 , which may be adjusted about an upright axis. Located between the chopper drum 22 and the conveyor unit 24 is a post-comminution device including two cooperating rollers 28 , which act to feed the conveyed material tangentially to the conveyor unit 24 .
According to the present invention, a device for automatic adjustment of the cutting length is provided which relieves the driver of the task of adjusting the cutting length to a value at which the chopped crop will be best suited as fodder for animals. The cut length of the chopped crop that is ejected from the discharge chute 26 depends on the rotating speed of the front press rollers 30 – 36 , on the speed of the chopper drum 22 , and on the number of blades attached to the chopper drum 22 . FIG. 2 shows a detailed illustration of the drive unit for the chopper drum 22 and the front press rollers 30 – 36 , and the device for automatic adjustment of the cutting length.
An internal combustion engine 42 operating at constant speed, while in a harvest mode, drives a transmission belt 46 via a pulley 44 which includes a disengageable coupling. The transmission belt 46 , in turn, drives a pulley 48 coupled to the chopper drum 22 . The chopper drum 22 includes a solid shaft 50 which drives a cogwheel or gear 52 which is meshed with a ring gear 54 of a planetary gear train 56 . The planetary gear train 56 includes a sun wheel 58 coupled to a hydraulic motor 60 . Planet gears 62 of the planetary gear train 56 , are coupled via a planet carrier with a cogwheel or gear 64 that drives the lower front press rollers 30 , 32 via an additional cogwheel or gear 66 , and drive the upper front press rollers 34 , 36 in a direction opposite that of the lower front press rollers, via additional cogwheels or gears 68 and 70 . Due to this configuration, the chopper drum 22 is driven at a constant rotational speed. The rotational speed of the front press rollers 30 – 36 depends on the rotational speed and direction of the hydraulic motor 60 .
The hydraulic motor 60 is connected, by a valve unit 72 , to a pressurized hydraulic fluid source 74 and to a hydraulic fluid supply tank 76 . The valve unit 72 is connected electrically to a control device 78 that can be actuated to control the valve unit 72 such that the hydraulic motor 60 will rotate at a rotational speed and direction specified by the control unit 78 . The control unit 78 is thus set up for continuous adjustment of the cutting length of the ejected material.
The device for automatic adjustment of the cutting length also comprises a sensor to measure the properties of the crop. In the illustrated embodiment, this sensor is a moisture sensor that is constructed from a microwave transmitter 40 and a microwave receiver 38 . The moisture sensor is mounted on the discharge chute 26 and operates via transmission, i.e., by transmitting radiation through the crop material passing through the discharge chute 26 . Details on the design and operation of this kind of moisture sensor are disclosed in DE 196 48 126 A, whose teaching is hereby incorporated by reference into the present application. The control device 78 is connected to the microwave transmitter 40 and the microwave receiver 38 . Based on the signals received from the microwave receiver 38 , the control device 78 evaluates the moisture content of the chopped crop. It then takes, from a memory unit 80 , a value for an optimal cutting length corresponding to the measured moisture content, and controls the valve unit 72 accordingly. The cutting length values might originate from tests or from experienced experts. In general, the cutting length will be greater the more moisture is contained in the chopped material. The memory unit 80 contains a table or database in which the cutting lengths or the rotational speed of the hydraulic motor 60 , as a function of the moisture in the harvested crop, are saved. Any intermediate values could be computed by interpolation. The use of algorithms, i.e., mathematic functions, would also be possible. Thus, even in the event of changes in the moisture of the harvested crop during the harvesting process, an optimal cutting length will be achieved without any delay and without manual intervention by the operator.
It should be mentioned that different modifications to the invention are possible. For example, it would be possible to use any type of moisture sensor instead of, or in addition to, the microwave sensor 38 , 40 , such as, for example, a capacitive sensor, an optical sensor, or a conductivity sensor. The sensor can also be located at a point on the harvesting machine 10 between the chopper drum 22 and the rotating track of the discharge chute 26 , or upstream from the chopper drum 22 . Furthermore, any other sensors can be used, alternatively or additionally, that ascertain the moisture or other parameters of the harvested crop, and whose signals can be used for adjusting of the cutting length. For example, the protein content of the chopped crop could be measured by a sensor operating in the near-infrared range. Based on the measurement value of the parameter and on information saved in the storage unit 80 , the cutting length could again be adjusted accordingly. If several sensors are used that measure different parameters of the chopped crop, then the control unit 78 will take from the storage unit 80 a cutting length value which best fits with the combination of measured parameters.
In certain cases, automatic adjustment of the cutting length can be switched off by an operator in the cab 18 and replaced with a manual setting.
Having described the preferred embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims. | It is proposed that a sensor ascertain a parameter of the harvested crop and send a signal used for changing the speed of feeding devices for the chopping and/or the speed of the chopping device in order for automatically obtaining a change in the length of the cut of the chopping device. | 0 |
BACKGROUND OF THE INVENTION
This invention relates generally to a retainer providing preload force for a bearing supporting a rotatable shaft and, more particularly, to a clamping ring providing a resilient preload so as to maintain an axial compressive rebound force on the bearing.
While this invention may be employed in many fields, it is particularly useful in conjunction with drive assemblies for heavy-duty earthmoving equipment, such as crawler tractors and the like. The final drive and the traction chains spaced on each side of the crawler tractor are subjected to substantial radial and axial thrust loads. These loads are the result of the high driving force required for operation and the erratic loading placed on the tractor drive because of rough terrain, side hill operation and directional changes.
In order to provide sufficient friction free support for the highly-loaded rotatable drive shafts, shock resistant, heavy-duty, tapered roller bearings are employed. If properly arranged and preloaded, these tapered roller bearings have inherent capability to efficiently accommodate both radial and axial thrust loads. In order to withstand high stress loads and deflection of components, it is vital that the required preloads on the tapered roller bearings be maintained so as to provide rigidity, positive support and extended service life for the bearings and the associated components.
In the prior art, it is a common practice to place a lock nut onto the rotating shaft to bear against the bearing and maintain prescribed bearing preloads. However, a conventional lock nut has a tendency to work loose during operation so that the bearing preload is diminished. In general, rotation of the lock nut ten degrees will alter the breakaway torque of the lock nut by approximately 100 foot-pounds.
It is possible to make periodic inspections and service adjustments of the bearing and lock nut. In some applications, ready accessibility makes these inspections and adjustments expedient. Even when the bearings and the lock nuts are not readily accessible, prudent inspections and periodic service should not be ignored. In the case of crawler-type tractors where the track chains and the drive sprockets must be removed, such periodic inspections are conducted at great expense. However, if service adjustments to the bearings and lock nuts are not made, serious damage and total failure of major components can result before operators or service personnel even become aware of the problem.
In order to eliminate the need for periodic servicing, numerous means have been devised to maintain the lock nut in fixed position on the shaft so that the bearing will be subjected to a constant preload force. Lock nuts have been employed which include integral synthetic plastic rings and/or plastic washers for securely gripping the coacting threads on the shaft. However, shaft deflection under high loads may cause this type of lock nut to loosen thereby resulting in partial or complete loss of vital bearing preloads.
A lockwasher which is fixedly secured to the lock nut is available, but is relatively expensive. The lockwasher has internal serrations to prevent rotation of the lockwasher on the shaft and tangs to engage the specially-designed lock nut. A key has been utilized between keyways formed in the lock nut and in the shaft to prevent relative rotation of the lock nut. A threaded split nut has been utilized. The use of shims in conjunction with a plate fixed to the shaft has also been employed to provide correct positioning of the bearing.
The above methods for obtaining and retaining a preload on the bearing securely fix the bearing against axial movement in one direction relative to the shaft. However, it has been found that it is desirable that the retainer or lock nut providing the preload force for the bearing have a degree of resiliency capable of maintaining an axial compressive rebound force even when it is loosened slightly. This compressive rebound force maintains a preload on the bearing races which is capable of assuring continued operating efficiency. Conventional lock nuts are not usually capable of providing this axial compressive rebound force.
SUMMARY OF THE INVENTION
The present invention is directed to overcoming one or more of the problems as set forth above.
According to the present invention, a bearing disposed about and rotatably supporting a shaft is held in preloaded position by a retainer having an axial bore with a wall in which circumferential grooves are formed so as to define alternating axially-spaced grooves and lands. The shaft, in turn, has a circumferential surface with spaced grooves formed therein so as to define alternating axially-spaced grooves and lands adjacent the desired preloaded position of the bearing. The retainer is moved radially into engagement with the shaft so that the respective coacting grooves and lands mesh, thereby securing the retainer to the shaft and resiliently securing the bearing against substantial axial movement.
One or both of the retainer and the shaft has sloped grooves and lands which are oblique to the shaft axis. Elastic deflection and deformation of the lands is effected by tightening the retainer on the shaft. The utilization of coacting distortable or deflectable sloped and annular ribs and lands provides a degree of resiliency capable of maintaining an axial compressive rebound force. An interference fit of the interleaved lands and grooves of the clamping ring and the shaft eliminates the need for close matching of the components.
In an exemplary embodiment of the invention, the clamping ring is formed from a plurality of separable sections. Means are provided for securing the sections together and for moving the sections radially inward so as to constrict the opening through the clamping ring and tighten the clamping ring on the shaft. Because of the radial shifting capability of the clamping ring sections, simple hand or pneumatic-actuated power wrenches can be utilized to secure the clamping ring on the shaft while press means axially applies the bearing preload.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a crawler tractor final drive partially in section in which a prior art self-locking retainer nut is employed to axially fix the inner race of a tapered roller bearing on a shaft;
FIG. 2 is a plan view of a retainer ring constructed in accordance with the invention which is operative to axially fix the inner race of the tapered roller bearing;
FIG. 3 is a fragmentary enlarged cross-sectional view of a bearing with the clamping ring in an unloaded position prior to the engagement of the sloping grooves and lands of the drive shaft;
FIG. 4 is a fragmentary enlarged cross-sectional view similar to FIG. 3 with the clamping ring securely engaged with the sloping grooves and the lands of the drive shaft; and
FIG. 5 is a fragmentary enlarged cross-sectional view of an alternative embodiment of the invention in which the slope of the corresponding lands and grooves has been reversed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a final drive assembly for a crawler tractor, generally designated 10, is seen to broadly include a steering clutch 11, a pinion gear 13 fixed on a shaft 14, a gear 16 which meshes and is rotated by the pinion gear 13, a sprocket drive shaft generally designated 17, fixed to the gear 16 and rotated thereby, a sprocket wheel 19 fixed to the drive shaft 17, and a complementing traction chain 20 driven continuously by the sprocket wheel 19. The tractor engine (not shown) provides power to the steering clutch 11 for operating the sprocket wheel 19.
The sprocket drive shaft 17 is journaled on one side of the gear 16 by suitable bearings 22 carried by the final drive housing 23. On the opposite side of the gear 16, the drive shaft 17 is supported by a tapered roller bearing assembly, generally designated 26, carried by the drive housing 23. The bearing assembly 26 has high radial and axial thrust load capability. The bearing assembly 26 includes an inner bearing 27 and an opposed outer bearing 28. The inner bearing 27 has an inner cone race 30 seated against an internal shoulder 31 formed in the drive shaft 17, an outer cup race 33 seated against a shoulder 34 of the drive housing 23, and tapered rollers 36 which are held in operative position between the cone race 30 and the cup race 33. Similarly, the outer bearing 28 has an inner cone race 38, an outer cup race 39, and tapered rollers 40.
In the prior art, a lock nut 42 was threaded onto the drive shaft 17 as seen in FIG. 1 so as to bear against the outboard end of the cone race 38 in order to provide the required preload on the bearing assembly so as to obtain positive support for the drive shaft 17. The sprocket wheel 19 is positioned outboard of the lock nut 42 and is fixed to the drive shaft 17 against rotation relative thereto via axially-extending splines 43. The sprocket wheel 19 is fixed against outward axial movement by a lock nut 45 which is threaded onto the outer end of the drive shaft 17 and bears against the sprocket wheel 19.
FIG. 2 illustrates a clamping ring or retainer, generally designated 50, which, in accordance with the invention, is employed in lieu of the lock nut 42 shown in the prior art structure of FIG. 1. With the exception of this substitution for the lock nut 42, a final drive assembly incorporating the invention is constructed in the manner as illustrated in FIG. 1. The clamping ring 50 is seen to include a pair of semicircular ring sections 51 and 52 which define an internal bore 54 when assembled. Each of the ring sections 51 and 52 includes radially-extending portions 56 and 57 through which bolts 60 and 61, respectively, extend to secure the ring sections 51 and 52 together.
As best seen in FIG. 3, a series of axially-spaced circumferential annular grooves 63 are formed in the wall of the bore 54 so as to define a surface having alternately axially-spaced grooves 63 and ribs or lands 64. The grooves 63 and therefore the lands 64 have a rectangular cross section and a prescribed radial depth.
Formed in the circumferential surface 66 of the drive shaft 17 adjacent the desired position of the outer end 67 of the cone race 38 is a series of axially-spaced grooves 69 which, in turn, define a series of axially-spaced ribs or lands 70. The grooves 69 and therefore the lands 70 have a parallelogram cross-section, the grooves 69 sloping radially inward and axially inward from the circumferential surface 66 so that they are disposed oblique to the shaft axis.
In FIG. 3, one section of the clamping ring 50 is being installed and is loaded by suitable press means indicated by arrow 72. The press means 72 forcefully urges the clamping ring 50 and therefore the cone race 38 inwardly to the desired preloaded position. When the clamping ring 50 is sufficiently loose on the drive shaft 17, the press means 72 can readily shift the outer bearing 28 and the clamping ring 50 axially inward without interference. When the loosely-coupled clamping ring 50 is properly positioned with the grooves 63 and the lands 64 of the clamping ring 50 being aligned with the respective lands 70 and grooves 69 of the drive shaft 17, the bolts 60 and 61 are tightened with sufficient torque to move the ring sections 51 and 52 together to effect engagement of the respective grooves and lands of the drive shaft 17 and the clamping ring 50. The inner surface 74 and the outer surface 75 of the clamping ring 50 are smooth to permit the clamping ring 50 to move radially inward towards the drive shaft 17 with relative ease regardless of the press force being employed.
As shown by FIG. 4, predetermined tightening of bolts 60 and 61 effects elastic deflection of the straight lands by the angled or sloping grooves 69 and lands 70 of shaft 17. Regardless of how many straight and sloped lands and grooves are employed to obtain the reaction loading force, the coacting relatively shallow grooves and lands must be of sufficient depth to result in a prescribed level of axial deflection of the straight lands 64. With sufficient elasticity and rebound, the displaced lands 64 will maintain a relatively high level of compressive force to keep the bearing assembly 26 properly preloaded. Disengagement of the coacting lands and grooves is unlikely because the bolts 60 and 61 are tightened with substantial torque and the deflected lands 64 of the clamping rings 50 are in shear radially and therefore tend to retard direct tensile loading and yielding of bolts 60 and 61.
The deflection required from the sloping and elastically displaced angular lands 64 need only be sufficient to compensate for any limited fatigue or yielding of the bolts 60 and 61 and any inherent tendency for the elastically displaced lands 64 to take some limited permanent set. Even with some yielding of the bolts 60 and 61 and some permanent setting occurring in the lands 64, sufficient rebound capability in the material will afford continuance of desired preloads on the tapered roller bearing assembly 26.
FIG. 5 illustrates how the angular or sloped and straight lands and grooves can be reversed in the coacting shaft 17' and clamping ring 50' while the elastic deflection are rebound force for maintenance of bearing preloads remains the same.
Elastic deflection of the angular and straight lands by tightening of bolts 60 and 61 will generate a rebound force ranging from 7,000 to 10,000 pounds axial preload on one or dual coacting tapered roller bearings. Preferably, the clamping ring 50 is made of softer material than the supporting shaft 17, and can even be made of material other than metal. Either the entire ring or just the lands can be made of metal or other synthetic man-made materials as long as a deformable material with elastic rebound capabilities is used. The interference fit of the interleaved lands and grooves of the clamping ring and reacting surface requires no close machining. Because of radial shifting capability of the ring sections, present simple hand- or pneumatic-actuated power wrenches can be utilized to secure the clamping rings under the bearing preload. | A retainer for resiliently applying a preload force to a bearing assembly rotatably supporting a shaft has a bore through which the shaft extends and is assembled from a plurality of separable sections. Formed in the wall of the bore are circumferential grooves which define lands therebetween. Similarly, circumferential grooves are formed about the shaft adjacent the end of the bearing assembly. One series of grooves are oblique to the shaft axis so that the respective lands are deflectively engaged when the retainer is radially closed about the shaft. The retainer is advantageously employed to maintain preloads on tapered roller bearings supporting the final drive shafts in heavy earthmoving equipment. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cathode ray tube (CRT), and more particularly, to a tensioned shadow mask with a color selection function.
2. Description of the Related Art
CRTs for television and computer displays employ a faceplate having on the inner side thereof a phosphor screen with a predetermined pattern, a mask and frame assembly which is an assembly of a shadow mask (hereinafter, simply referred to as a mask) and a frame, and is installed on the inner side of the faceplate, a funnel connected to the faceplate, which has a neck portion and a cone portion, and an electron gun inserted in the neck portion of the funnel, for emitting electron beams through apertures of the mask to excite the phosphor screen, and a deflection yoke installed around the cone portion of the funnel, for deflecting electron beams from the electron gun.
In a CRT having the above configuration, the mask for accurate landing of three electron beams emitted from the electron gun on each phosphor layer of the phosphor screen includes; a dot mask with substantially circular apertures a slot mask with parallel elongated apertures, and a tensioned mask to which tension is applied from opposite sides thereof, and having a series of parallel stripes separated by slits through which electron beams pass.
FIG. 1 shows an example of a tensioned mask. As shown in FIG. 1, the tensioned mask includes a plurality of strips 22 separated by slits 21 having a predetermined interval, and a plurality of tie bars 33 which interconnect the adjacent strips. The tensioned mask is supported in tension by a frame (not shown) of the tensioned mask.
In the mask, the tie bars 23 which interconnect the adjacent strips 22 can reduce a howling phenomenon, which occurs due to mask vibration from external impact, and unacceptable Poisson's contraction. However, if the vertical pitch of the tie bars 23 is too large, that is, if the vertical pitch (PV) of the tie bars 23 is twice or more the horizontal pitch (PH) thereof, a reflection image of the tie bars 23 is shown on the screen, which is unpleasant to viewers.
To avoid this problem, U.S. Pat. No. 4,926,089 discloses a tensioned mask as shown FIG. 2 . As shown FIG. 2, the tensioned mask includes a plurality of strips 31 separated by slits 32 having a predetermined interval, and tie bars 33 which interconnect the adjacent strips 31 . Also, dummy bridges 34 , which extend partially between but not interconnecting adjacent strips, are disposed between the adjacent tie bars 34 and separate each slit 32 into sub-slits having a predetermined interval.
In the tensioned mask, due to a technical problem in mask pattern formation, the width W 1 of the dummy bridges 34 is smaller than the width W 2 of the tie bars 33 . Thus, the reflection images by the dummy bridges 34 and the tie bars 33 have a slight difference in intensity of light. This difference raises the problem of tie bar visibility, thus deteriorating display image and making viewing unpleasant.
SUMMARY OF THE INVENTION
To solve the above problems, an object of the present is to provide a tensioned shadow mask for a cathode ray tube (CRT), capable of eliminating the problem of tie bar visibility while enhancing display image visibility.
In one embodiment of the present invention, there are provided a tensioned shadow mask for a CRT, comprising: a series of parallel strips separated by slits having a predetermined interval; a plurality of tie bars interconnecting adjacent strips to define a plurality of slits at predetermined intervals; and a plurality of dummy bridges disposed between adjacent tie bars, extending from one of the strips to the other but not interconnecting the adjacent strips, wherein the dummy bridges are longer than the tie bars in the longitudinal direction of the strips.
In the tensioned shadow mask according to the present invention, the area of the dummy bridges is equal to that of the tie bars, or the area difference between the dummy bridges and the tie bars is in a predetermined range. The dummy bridges may extend from a strip to the next strip but not intersecting the adjacent strips, or the dummy bridges may alternately extend from the adjacent strips such that a first dummy bridge extends from one of the adjacent strips and the next dummy bridge extends from the other of the adjacent strips.
BRIEF DESCRIPTION OF THE DRAWING
The above object and advantages of the present invention will become more apparent by describing in detail preferred embodiments thereof with reference to the attached drawings in which:
FIG. 1 is a plan view of a conventional tensioned mask for a color cathode ray tube (CRT);
FIG. 2 is a partial enlarged view of the conventional tensioned mask, illustrating an aperture configuration thereof;
FIG. 3 is an exploded perspective view illustrating a state where a tensioned mask for a CRT according to the present invention is secured to a frame;
FIG. 4 is a partial enlarged view of the tensioned mask of FIG. 3, illustrating an aperture configuration thereof;
FIG. 5 is a partial enlarged plan views illustrating examples of the tensioned mask according to the present invention; and
FIGS. 6 through 15 are photos illustrating the visibility of tie bars reflected on a phosphor screen with respect to the area difference between the tie bars and dummy bridges of tensioned masks.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 3 and 4, a tensioned mask and frame assembly includes a tensioned mask 40 and a frame 50 for supporting the tensioned mask 40 in tension. In the tension mask 40 , which is formed of a 50-100 μm-thick foil, a series of strips 41 each having a width W 1 of 190 μm are separated by slits 42 having a width of 60 μm. The slits 42 are separated by tie bars 43 which interconnect adjacent strips 41 ′ and 41 ″. The tie bars 43 are arranged in a staggered fashion in the transverse direction of the tensioned mask 40 . Also, a plurality of dummy bridges 44 , by which each slit 42 is separated into sub-slits having a predetermined interval, are disposed between the tie bars 43 , wherein the dummy bridges 44 extend from one of the adjacent strips 41 ′ and 41 ″ to the other but not interconnecting the adjacent strips 41 ′ and 41 ″.
FIG. 5 shows another tensioned mask having the strips with dummy bridges arranged in a different manner from that of FIG. 3 . As shown in FIG. 5, dummy bridges 45 alternately extend from one of the adjacent strips 41 ′ and 41 ″ such that a first dummy bridge extends from one of the adjacent strips 41 ′ and 41 ″ and the next dummy bridge extends from the other of the adjacent strips 41 ′ and 41 ″.
In the above embodiments, the length L 1 of the dummy bridges 44 and 45 is larger than the length L 2 of the tie bars 43 , and the width W 4 of the dummy bridges 44 or 45 is smaller than the width W 5 of the tie bars 43 . However, the area A 1 (=L 1 ×W 4 ) of the dummy bridges 44 is equal to the area A 2 (=L 2 ×W 5 ) of the tie bars 43 , or the area difference between the dummy bridges 44 and the tie bars 43 is in a predetermined range. The area of the dummy bridges 44 or 45 may differ from that of the tie bars 43 . However, it is preferable that the area of the dummy bridges 44 or 45 is equal to that of the tie bars 43 , so that the tie bars will not visibly stand out. Also, the area of the dummy bridges 44 or 45 may be smaller or larger than that of the tie bars 43 , as long as the area difference is in the range of 30 percent, which is expressed by |(A 1 −A 2 )|/A 2 ≦0.3.
Also, as shown in FIG. 3, the frame 50 of the tensioned mask and frame assembly comprises a pair of supports 51 and 52 spaced a predetermined distance, for supporting the longer side edges of the tensioned mask 40 , and a pair of elastic members 53 and 54 for applying tension to the tension mask 40 , wherein both ends of the elastic members 53 and 54 are fixed to the supports 51 and 52 . The frame configuration is not limited to the above configuration, and any configuration capable of acting tension on the tensioned mask can be adopted.
The tensioned mask is installed at the inner side of the faceplate, at a predetermined distance from the phosphor screen, being supported by the frame, provides a color selection function for accurate passage through the slits 42 and landing on the phosphor screen of the electron beams emitted from the electron gun.
The electron beams may be shielded by the tie bars 43 which define the slits 42 at predetermined intervals, or by the dummy bridges 44 or 45 , which hinders complete excitation of the phosphor screen, thus resulting in a reflection image on the screen. However, the length L 2 of the tie bars 43 is larger than the length L 1 of the dummy bridges 44 or 45 , and the area of the tie bars 43 is nearly equal to that of the dummy bridges 44 or 45 , so that the reflection image area due to the tie bars 43 , which corresponds to a nonexcited region of the phosphor screen, is nearly the same as that due to the dummy bridges 44 or 45 . As a result, a real image and a reflection image are uniformly distributed over the screen, so that viewers scarcely perceive the reflection image, thereby improving appearance uniformity. The reflection image distribution can be controlled by varying the number of tie bars 43 and dummy bridges 44 or 45 .
The tensioned mask of a CRT according to the present invention, having the above structure, is characterized in that the area of the dummy bridges is equal or similar to that of the tie bars, so that a decrease in resolution due to the reflection image of the tie bars can be avoided with an improved appearance uniformity.
The following embodiments are provided so that this disclosure will be thorough and complete.
EXPERIMENTAL EXAMPLE 1
The appearance uniformity with respect to the area difference between the tie bars and the dummy bridges was observed by varying the length of the dummy bridges relative to the length of the tie bars in a tensioned mask of a CRT for monitors. The result is shown in Table 1.
TABLE 1
Tie bar
Dummy bridge
Length
Width
Area
Length
Width
Area
Area
Appearance
Sample
(μm)
(μm)
(μm 2 )
(μm)
(μm)
(μm 2 )
ratio (%)
Uniformity
1
60
60
3,600
60
30
1,800
50
poor
2
60
60
3,600
90
30
1,800
75
moderate
3
60
60
3,600
120
30
1,800
100
good
4
60
60
3,600
150
30
1,800
125
moderate
As can be noted from Table 1, the appearance uniformity is acceptable when the area of the tie bars is in a range greater than 70% and less than 130% of the area of the tie bars.
FIGS. 6 through 11 are photos illustrating the visibility of tie bars reflected on the phosphor screen, with respect to the area difference between the tie bars and dummy bridges of tensioned masks shown in Table 1. In particular, FIG. 7 is a macro photo in a case when the area of the dummy bridges is 50% of that of the tie bars (Sample 1 of Table 1), and FIG. 6 is a 20×-magnified photo of FIG. 7 . As shown in FIGS. 6 and 7, distinct tie bar shadows appear on the phosphor screen.
FIG. 9 is a macro photo showing the tie bar visibility on the phosphor screen when the area of the dummy bridges is 75% of that of the tie bar (Sample 2 of Table 1), and FIG. 8 is a 20×-magnified photo of FIG. 9 . As shown in FIG. 8, the sizes of the reflection image by the tie bars and the dummy bridges appear to be equal to each other, showing a slight difference in intensity of light therebetween. Also, as shown in FIG. 9, it is difficult to distinguish the tie bar shadows on the phosphor screen from the dummy bridges shadows thereon.
FIG. 11 is a macro photo showing the tie bar visibility on the phosphor screen when there is no difference in area between the tie bars and the dummy bridges (Sample 3 of Table 1), and FIG. 10 is a 20×-magnified photo of FIG. 11 . In FIG. 10, the dummy bridges that are enlarged in the longitudinal direction so as to make the area of the dummy bridges equal to that of the tie bars are visible. As shown in FIG. 11, it is difficult to distinguish the tie bar shadows from the dummy bridges shadows, and the reflection images of the tie bars and dummy bridges show uniform intensity of light.
Although photos of the Sample 4 in Table 1, in which the area of the dummy bridges is 125% of that of the tie bars, were not taken, the size of the reflection image of the dummy bridges on the phosphor screen was large whereas that of the tie bars was small, compared to the Sample 3. Furthermore, the reflection image of the tie bars were shown as white dots on the screen.
EXPERIMENTAL EXAMPLE 2
The appearance uniformity with respect to the area difference between the tie bars and the dummy bridges was observed by varying the length of the dummy bridges relative to the length of the tie bars in a tensioned mask of a CRT for a television. The result is shown in Table 2.
TABLE 2
Tie bar
Dummy bridge
Length
Width
Area
Length
Width
Area
Area
Appearance
Sample
(μm)
(μm)
(μm 2 )
(μm)
(μm)
(μm 2 )
ratio (%)
Uniformity
1
80
195
15,600
80
145
8,700
55
poor
2
80
195
15,600
80
145
11,600
74
moderate
3
80
195
15,600
108
145
15,660
100.3
good
4
80
195
15,600
140
145
20,300
130.1
moderate
As can be understood from Table 2, the appearance uniformity is acceptable when the area difference between the tie bars and dummy bridges is in the range of 30%.
FIGS. 12 through 15 are photos illustrating the visibility of tie bars reflected on the phosphor screen, with respect to the area difference between the tie bars and dummy bridges of tensioned masks shown in Table 2. In particular, FIG. 13 is a macro photo in a case when the area of the dummy bridges is 55% of that of the tie bars (Sample 1 of Table 2), and FIG. 12 is a 10×-magnified photo of FIG. 13 . As shown in FIGS. 12 and 13, although the resolution is poor, due to the large horizontal pitches of the phosphor pattern and the slits of the tensioned mask for a television, compared to those for monitors (Experimental Example 1), distinct tie bar shadows appear on the screen.
FIG. 15 is a macro photo showing the tie bar visibility on the phosphor screen when the area of the dummy bridges is 74% of that of the tie bars (Sample 2 of Table 2), and FIG. 14 is a 10×-magnified photo of FIG. 15 . In FIG. 14, the dummy bridges that are enlarged in the longitudinal direction so as to make the area of the dummy bridges equal to that of the tie bars are distinct. As shown in FIG. 15, the reflection images of the tie bars and dummy tie bars have uniform intensity of light, so that it is difficult to distinguish the reflection image of the tie bars from that of the dummy tie bars, thus improving the appearance uniformity.
Although photos of the Sample 4 in Table 2, in which the area of the dummy bridges is 130% or more larger than that of the tie bars, were not taken, the size of the reflection image of the dummy bridges on the phosphor screen was large whereas that of the tie bars was small, compared to the samples described with reference to photos. Furthermore, the reflection image of the tie bars was shown as which dots the screen.
While the present invention has been illustrated and described with reference to specific embodiments, further modifications and alterations within the spirit and scope of this invention as defined by the appended claims will become evident to those skilled in the art. | A tensioned shadow mask for a cathode ray tube (CRT), including: a series of parallel strips separated by slits having a predetermined interval; a plurality of tie bars interconnecting adjacent strips to define a plurality of slits at predetermined intervals; and a plurality of dummy bridges disposed between adjacent tie bars, extending from one of the strips to the other but not interconnecting the adjacent strips, wherein a length of the dummy bridges is greater than a length of the tie bars in the longitudinal direction of the strips. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 12/495,356 filed on Jun. 30, 2009, the disclosure of which is incorporated herein in its entirety by reference.
TECHNICAL FIELD
[0002] The presently disclosed technologies are directed to an apparatus for and a method of registering the lateral position of a sheet in a media handling assembly, such as a printing system, using adjustable idler rollers.
BACKGROUND
[0003] In media handling assemblies, particularly in printing systems, accurate and reliable registration of the substrate media as it is transferred in a process direction is desirable. In particular, accurate registration of the substrate media, such as a sheet of paper, as it is delivered at a target time to an image transfer zone will improve the overall printing process. The substrate media is generally conveyed within the system in a process direction. However, often the substrate media can shift in a cross-process direction that is lateral to the process direction or even acquire an angular orientation, referred herein as “skew,” such that its opposed linear edges are no longer parallel to the process direction. Thus, there are three degrees of freedom in which the substrate media can move, which need to be controlled in order to achieve accurate delivery thereof. A slight lateral misalignment, skew or error in the arrival time of the substrate media through a critical processing phase can lead to errors, such as image and/or color registration errors. Also, as the substrate media is transferred between sections of the media handling assembly, the amount of positioning error can increase or accumulate.
[0004] Contemporary media handling systems attempt to achieve position registration of sheets by separately varying the speeds of spaced apart drive wheels to correct for skew and/or lateral mispositioning of the sheet. Such systems that separately vary the drive wheel speeds are commonly referred to as differential drive systems. The drive wheels are used with cooperating idler rollers for engaging the substrate media there between. The differential drive wheels with the idler rollers are together referred to as differential nip assemblies.
[0005] Examples of typical sheet registration and deskewing systems are disclosed in U.S. Pat. Nos. 5,094,442, 6,533,268, 6,575,458 and 7,422,211, commonly assigned to the assignee of record herein, namely Xerox Corporation, the disclosures of which are each incorporated herein by reference. While these systems particularly relate to printing systems, similar paper handling techniques apply to other media handling assemblies. Such contemporary systems transport a sheet and deliver it at a target time to a target location, based on measurements from the sheet sensors. The target location can be a particular point in a transfer zone, a hand-off point to a downstream nip assembly or any other target location within the media handling assembly. Typically, based on sheet sensor measurements, a controller can adjust the sheet velocity to steer the sheet to a target location at a desired time. The controller uses the differential drive system to correct primarily for skewed positional errors detected for the sheet. Temporarily driving two motors at slightly different rotational speeds induces a rotational sheet motion that is used to eliminate/correct for detected skew and/or process timing errors. The resultant dynamics are nonlinear and make closed-loop feedback control complex and difficult to execute.
[0006] Other contemporary systems use alternative cross-process correction techniques, such as nip assemblies that translate laterally in order to shift the sheet while engaged within the nips. However, laterally translating nip assemblies include driven wheels mounted on a moveable carriage assembly. Driven wheels inherently include motors, gears and/or belts associated therewith, thus such assemblies are complex, costly, prone to mechanical failure and difficult to repair. Also, having to reset the mechanical carriage between sheets limits the speeds and inter-copy gaps at which the system can function.
[0007] Another alternative system uses nip assemblies with fixed angled driven wheels that drive the sheets into a straight edge fence or rail, thereby correcting both cross-process and skew errors simultaneously. However, such systems are limited in the size and type of substrate media being handled and are prone to marking, buckling or damaging the substrate media.
[0008] Accordingly, it would be desirable to provide an apparatus for and a method of registering the lateral position of a sheet in a media handling assembly, which overcomes the shortcoming of the prior art.
SUMMARY
[0009] According to aspects described herein, there is disclosed an apparatus for laterally registering a sheet moved in a process direction along a transport path in a media handling assembly. A lateral direction extends perpendicular to the process direction. The assembly including at least two nip assemblies spaced apart from one another along a first axis extending in the lateral direction. Each nip assembly including a driven wheel and an idler roller. The driven wheel rotatably supported about the first axis and the idler roller cooperating with the driven wheel to engage the sheet there between. The idler roller rotatably supported about a second axis, with the second axis being selectively moveable between a first and second orientation while the sheet is moved along the transport path. In the first orientation, the second axis extending parallel to the first axis, and in the second orientation the second axis extending at an oblique angle to the first axis. The selective movement of the second axis pivoting about a third axis substantially extending through a centerline common to both the driven wheel and the idler roller of each nip assembly.
[0010] Additionally, the selective movement of at least one of the at least two nip assemblies can be independent from the selective movement of another of the at least two nip assemblies. The selective movement of the at least two nip assemblies can occur in unison. In the second orientation the oblique angle can be limited to not exceed approximately 10 degrees. Also, at least one of the at least two nip assemblies can be disposed in the first orientation while another of at least two nip assemblies can be disposed in the second orientation. Further, a first surface material of the drive wheel can be more compliant than a second surface material of the idler roll.
[0011] Also, the apparatus can include a linkage mechanism coupling the idler rollers of the at least two nip assemblies for the selective movement in unison. Additionally, the apparatus can include a controller for actuating the idler roller to move between the first orientation and the second orientation. Further, the apparatus can include at least one sensor for detecting a lateral position of the sheet. Further still, the apparatus can include a differential drive system operatively connected to the driven wheels of at least two nip assemblies. The differential drive system can impart different rotational velocities to each driven wheel.
[0012] According to other aspects described herein, there is a method of registering a lateral position of a sheet moved substantially in a process direction along a transport path in a media handling assembly. A lateral direction extending perpendicular to the process direction. The method including providing at least two nip assemblies, where each nip assembly includes a driven wheel and an idler roller. The driven wheel being rotatably supported about a first axis extending in the lateral direction. The idler roller cooperating with the driven wheel to engage the sheet there between. The idler roller being rotatably supported about a second axis. Also, the method including pivoting the idler roller about a third axis substantially extending through a centerline common to both the driven wheel and the idler roller. Whereby the second axis of rotation pivots between a first and second orientation. In one of the first and second orientations the second axis extends parallel to the first axis and in the other of the first and second orientations the second axis extends oblique to the first axis.
[0013] Additionally, the idler roller pivoting of at least one of the at least two nip assemblies can be independent from the idler roller pivoting of another of the at least two nip assemblies. Also, the method can further include measuring a lateral position of the sheet during and/or after the idler roller pivoting for continuous pivotal adjustment of the idler roller. The at least two nip assemblies can be spaced apart from one another along the first axis. The idler roller pivoting of the at least two nip assemblies can occur in unison. Further, an actuating linkage mechanism can be provided for pivoting the at least two nip assemblies in unison. Further still, each idler roller of the at least two nip assemblies can pivot a different degree of rotation. The method can further include driving a first driven wheel of the at least two nip assemblies at a different rotational speed than a second driven wheel of the at least two nip assemblies for imparting a rotational skew velocity to the sheet.
[0014] These and other aspects, objectives, features, and advantages of the disclosed technologies will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a partially schematic isometric view of two nip assemblies for laterally registering a sheet in a media handling assembly in accordance with an aspect of the disclosed technologies.
[0016] FIG. 2 is a side view of a basic nip assembly.
[0017] FIG. 3 is a top view of the nip assembly of FIG. 2 .
[0018] FIG. 4 is a top view of the nip assembly of FIG. 2 , with an idler roller skewed relative to the driven wheel in accordance with an aspect of the disclosed technologies.
[0019] FIG. 5 is a plan view of an adjustable idler assembly in accordance with an aspect of the disclosed technologies.
[0020] FIG. 6 is a plan view of the assembly of FIG. 5 , with the idler rollers skewed relative to the driven wheels in accordance with an aspect of the disclosed technologies.
[0021] FIG. 7 is a plan view of the assembly of FIG. 6 in conjunction with a system controller, sensors and a handled sheet in accordance with an aspect of the disclosed technologies.
[0022] FIG. 8 is a schematic block diagram of a lateral registration control method in accordance with an aspect of the disclosed technologies.
DETAILED DESCRIPTION
[0023] Describing now in further detail these exemplary embodiments with reference to the Figures, as described above the accurate sheet registration system and method are typically used in a select location or locations of the paper path or paths of various conventional media handling assemblies. Thus, only a portion of an exemplary media handling assembly path is illustrated herein.
[0024] As used herein, a “printer,” “printing assembly” or “printing system” refers to one or more devices used to generate “printouts” or a print outputting function, which refers to the reproduction of information on “substrate media” for any purpose. A “printer,” “printing assembly” or “printing system” as used herein encompasses any apparatus, such as a digital copier, bookmaking machine, facsimile machine, multi-function machine, etc. which performs a print outputting function.
[0025] A printer, printing assembly or printing system can use an “electrostatographic process” to generate printouts, which refers to forming and using electrostatic charged patterns to record and reproduce information, a “xerographic process”, which refers to the use of a resinous powder on an electrically charged plate record and reproduce information, or other suitable processes for generating printouts, such as an ink jet process, a liquid ink process, a solid ink process, and the like. Also, such a printing system can print and/or handle either monochrome or color image data.
[0026] As used herein, “substrate media” refers to, for example, paper, transparencies, parchment, film, fabric, plastic, photo-finishing papers or other coated or non-coated substrates on which information can be reproduced, preferably in the form of a sheet or web. While specific reference herein is made to a sheet or paper, it should be understood that any substrate media in the form of a sheet amounts to a reasonable equivalent thereto. Also, the “leading edge” of a substrate media refers to an edge of the sheet that is furthest downstream in the process direction. The “lateral edge” or “lateral edges” of the substrate media refers to one or more of the opposed side edges of the sheet, extending substantially in the process direction.
[0027] As used herein, a “media handling assembly” refers to one or more devices used for handling and/or transporting substrate media, including feeding, printing, finishing, registration and transport systems.
[0028] As used herein, “sensor” refers to a device that responds to a physical stimulus and transmits a resulting impulse for the measurement and/or operation of controls. Such sensors include those that use pressure, light, motion, heat, sound and magnetism. Also, each of such sensors as refers to herein can include one or more point sensors and/or array sensors for detecting and/or measuring characteristics of a substrate media, such as speed, orientation, process or cross-process position and even the size of the substrate media. Thus, reference herein to a “sensor” can include more than one sensor.
[0029] As used herein, “skew” refers to a physical orientation of a substrate media relative to a process direction. In particular, skew refers to a misalignment, slant or oblique orientation of an edge of the substrate media relative to a process direction.
[0030] As used herein, the terms “process” and “process direction” refer to a process of moving, transporting and/or handling a substrate media. The process direction is a flow path (also described as a transport path) the substrate media moves in during the process. A “cross-process direction” is perpendicular to the process direction and generally extends parallel to the web of the substrate media.
[0031] FIG. 1 depicts a partially schematic isometric view of an apparatus for laterally registering a sheet handled in a printing system. It should be noted that the partially schematic drawings herein are not to scale. In FIG. 1 , the process direction 10 corresponds to the primary direction of flow of the sheet 5 , indicated by a large arrow, heading from an upstream location toward a downstream location. The cross-process or lateral direction 15 extends perpendicular to the process direction. In this way, the sheet 5 generally travels across a pair of nip assemblies 30 toward a transfer area 20 . It should be understood that transfer area 20 , could include an image transfer system, such as the belt shown, an image transfer drum or other media handling assembly not limited to image transfer systems. Each nip assembly 30 includes a driven wheel 41 and idler roller 51 that cooperate to engage the sheet 5 there between, thereby moving the sheet 5 in the overall assembly. The driven wheel 41 is rotatably driven by a motor assembly coupled thereto by gears, belts, pulleys or other known methods. The idler roller 51 is rotatably mounted to freely rotate as a sheet 5 engages it and passes through the nip 30 . In order to grab and/or engage the sheet 5 , one or both of the driven wheel 41 and idler roller 51 are biased toward one another, such as the biasing force 45 shown.
[0032] FIG. 2 shows a side view of a basic nip assembly 30 , which includes a driven wheel 41 that cooperates with an idler roller 51 to induce sheet velocity 11 . The driven wheel 41 includes an outer surface material 43 that is generally softer or more compliant than the inner drive roller 42 or the idler roller 51 . For example, the outer surface material 43 can be silicone rubber or a similarly compliant material. In contrast, the idler roller 51 can be formed of a less compliant surface, such as a hard metal. As in contemporary systems, the driven wheel 41 , and more particularly the drive roller 42 is coupled to a drive mechanism that is regulated by a programmable and/or automated controller (not shown). The diameter or width of the individual drive or idler rollers can be varied as desired and/or as necessary for the particular application. It is generally understood in the media handling arts that the sheet velocity 11 can differ from the drive roller velocity 44 due to the compliance of the elastomer of the outer surface material 43 . In contrast, the less compliant idler roller velocity 54 is driven by frictional forces between the sheet and the hard roller 51 surface. Thus, the idler roller velocity 54 for a hard surface idler roller 51 generally matches or is generally closer to the sheet velocity 11 , than the drive roller velocity 44 . Alternatively, the idler roller 51 could be coated or provided with a soft or compliant outer surface. In one such alternative arrangement, the compliant idler roller 51 can still be less compliant than the driven wheel. In a further alternative embodiment, the more compliant outer surface material is only used on the idler roller 51 , with a less compliant or non-compliant (hard) driven wheel 41 .
[0033] FIGS. 3 and 4 depict a top view of the basic nip assembly 30 . FIG. 3 shows the idler roller 51 in different orientations than that shown in FIG. 4 , relative to the driven wheel 41 . It should be noted that the widths of the driven wheel 41 and idler roller 51 are shown to be drastically different for illustrative purposes. The actual widths are a matter of design choice. In FIG. 3 , the driven wheel 41 includes a rotational axis 40 that is parallel to the rotational axis 50 of the idler roller 51 . Due to the top view orientation of FIG. 3 , the two rotational axis 40 , 50 appear as a single axis, however their offset relationship is more clearly shown in FIG. 1 . In particular, FIG. 1 shows the rotational axis 40 of both drive wheels 41 being offset (vertically in the configuration shown) from both idler roller rotational axis 50 , although they remain parallel. In FIG. 4 , the idler roller 51 has been pivoted about an axis extending substantially through a centerline common to both the driven wheel 41 and the idler roller 51 , in accordance with an aspect of the disclosed technologies. In the top view orientation shown in FIG. 4 , the pivoting axis extends directly into and out from the page. The pivoting axis is generally perpendicular to both the process direction 10 and the lateral direction 15 . As shown in FIG. 1 , the pivoting axis 55 extends vertically, which is perpendicular to the horizontal sheet path shown. A non-horizontal sheet path would mean the axis 55 extends in a non-vertical direction, but still perpendicular to both the process direction and the lateral direction. With regard to FIG. 4 , the pivoted idler roller 51 creates an angle α between the driven wheel rotational axis 40 and the idler roller rotational axis 50 . Thus, when angle α is not zero, the idler axis 50 is said to be at an oblique angle to the driven wheel axis 40 . The same angle α is thereby created between the process direction 10 and idler velocity vector 12 .
[0034] By changing the angle α between the driven wheel rotational axis 40 and the idler roller rotational axis 50 , lateral sheet correction can be achieved. Also, such induced lateral sheet motion is decoupling motion from the process and/or skew direction motions generated by traditional systems. In accordance with an aspect of the disclosed technologies, the more compliant driven wheel 41 imparts a process direction movement, while the less compliant angled idler rollers 51 translate that process direction movement into a lateral component imparted by velocity vector 12 . The angled idler rollers 51 thus create “nip and paper dynamics” that can be used for lateral registration correction. Also, by pivoting the idler roller axis 50 relative to the driven wheel axis 40 , on a sheet-by-sheet basis, lateral registration can be maintained for each sheet even though lateral sheet drift can vary among sheets. A similar but somewhat different nip and paper dynamics can be achieved by switching the more compliant sheet engagement surface to the idler rollers. As long as the axis of rotation of the driven wheel and/or the idler roller can be changed relative to one another, so that they no longer rotate on parallel axis, lateral sheet movement can be induced.
[0035] As the angle α is increased from zero, the rate of induced sheet lateral movement should also increase. However, when a hard non-compliant roller or wheel is used, the rate of induced sheet lateral movement will reach a peak or limit once the angle α gets too large. Thus, depending on the materials used for the nip sheet engagement surfaces, the angle α can have a limit value after which no additional increase in the rate of lateral movement for the sheet can be induced. This is mainly due to sheet slippage with the low coefficient of friction non-compliant nip engagement surfaces. Additionally, the composition and texture of the sheet, as well as the sheet velocity can also effect such a limit value for the angle α. Accordingly, it can be advantageous to limit how much pivot about the pivoting axis 55 is allowed to be actuated between the driven wheel 41 and the idler roller 51 . Thus, a predesignated limit value can be assigned or set for a maximum oblique angle α.
[0036] FIGS. 5 and 6 depict a linkage mechanism 60 for adjusting idler angles of both nip assemblies in unison. The linkage mechanism 60 includes individual idler frames 62 for each idler roller 51 . The idler frames 62 are shown as a rectangular rigid structure with a central shaft 63 rotationally supporting the idler roller 51 . Each of these central shafts 63 coincide with the idler roller axis 50 , discussed with regard to FIGS. 1 , 3 and 4 . Also, opposed sides of the idler frame 62 include a pivotal coupling joint 64 for linking the two idler frames 62 in order for them to move in unison. The use of further linkage bars 65 , 66 and coupling joints 64 link the two frames 62 . Thus, opposed sides of the frames 62 include process direction linkage bars 65 . Each of the process direction linkage bars 65 is pivotally connected through a coupling joint 64 , on one side by the frame 62 and on its opposite side by a lateral linkage bar 66 . The lateral linkage bars 66 are pivotally coupled through a coupling joint 64 at opposed ends by process direction linkage bars 65 that connect to separate frames 62 . By providing a mechanism (not shown) for inducing opposite lateral 15 movement of the two linkage bars 66 , the frames 62 will pivot. Thus, as shown in FIG. 6 , by shifting the right side (downstream side) lateral linkage bar 66 upwardly and the left side (upstream side) lateral linkage bar 66 downwardly, both frames 62 pivot. Accordingly, once the frames 62 are pivoted relative to the driven wheels 41 , the idler velocity vector 12 is no longer parallel with the process direction and will thus induce lateral sheet movement. It should be understood that although a rectangular and/or linear linkage mechanism structure is shown, alternative structures can be used to achieve the same or similar unified movement.
[0037] FIG. 7 depicts an alternative embodiment registration system 100 where the individual idler frames 62 are not coupled to one another, but rather are separately actuated by a controller 70 . FIG. 7 also shows a sheet 5 conveyed in the process direction 10 through two nip assemblies used in conjunction with edge sensors 22 , 24 , all coupled to a controller 70 . Edge sensors 22 , 24 can be used to detect the lateral and process position, as well as orientation, of the sheet 5 relative to the nip assemblies. While two sensors 22 , 24 are shown, it should be understood that fewer or greater numbers of sensors could be used, depending on the type of sensor, the desired accuracy of measurement and redundancy needed or preferred. For example, a pressure or optical sensor could be used to detect when the lateral edge of the sheet passes over each individual sensor. Additionally, the sensors can be positioned further upstream or closer to the nip assemblies, as desired. It should be appreciated that any sheet sensing system can be used to detect the position and/or other characteristics of the substrate media in accordance with the disclosed technologies. Once the actual lateral sheet position is measured by the sensors 22 , 24 , the controller 70 can actuate one or both of the idler frames 62 in order to correct the lateral sheet position. In the previous embodiment where both idler frames 62 moved in unison, the controller 70 would actuate the linkage mechanism 60 to correct the lateral sheet position.
[0038] Additionally, by measuring the sheet lateral position at the sensors 22 , 24 and knowing the spacing of the sensors 22 , 24 , skew of the sheet 5 relative to the nip assemblies 30 can be calculated, as is known in the art. Alternatively, a similar skew orientation of the sheet 5 can be detected by other sensor systems, disposed upstream of the nips 30 . For example, a pair of point sensors or one or more array sensors capable of measuring sheet position and/or skew can alternatively be provided.
[0039] A controller 70 is used to receive sheet information from edge sensors 22 , 24 and any other available input that can provide useful information regarding the sheet(s) 5 being handled in the system. The controller 70 can include one or more processing devices capable of individually or collectively receiving signals from input devices, outputting signals to control devices and processing those signals in accordance with a rules-based set of instructions. The controller 70 can then transmit signals to one or more actuation systems. For example a rack and gear assembly could be actuated by the controller 70 in order to shift the configuration of the idler frames 62 between that shown in FIGS. 5 and 6 . Also, the controller 70 can activate a differential drive system for correcting skew or process speeds. Thus, based on the position/orientation of the sheet input into the controller 70 , a “correction profile” is calculated to eliminate the detected positional and/or timing error(s).
[0040] FIG. 8 shows a schematic block diagram of a lateral registration control method used in accordance with an embodiment of the disclosed technologies. The registration method includes a predesignated or desired sheet position for proper registration within the system. Such positional information particularly includes lateral sheet position, but can additionally include sheet skew and process position/timing information. The method initiates at 80 when a lateral sheet position error is noted as compared to the predesignated lateral sheet position. The controller 70 is provided with a lateral sheet position measurement, such as from edge sensors 22 , 24 , which indicates the noted error. Additionally, the lateral edge sensors 22 , 24 can provide controller 70 with skew and/or process position measurements. The controller 70 then acts to correct the measured lateral positioning error by transmitting a command to angle the idler rollers 51 relative to the driven wheels 41 . Preferably, the idler rollers 51 can be angled in either lateral direction (inboard or outboard) relative to the process direction. Both of the idler rollers 51 can be pivoted by the same angle in unison through a linkage mechanism or independently pivoted the same amount. The angle α of the idler rollers is selected based on the amount of lateral movement needed to correct the sheet position. Alternatively, a predesignated idler roller angle α can be used, such as 10 degrees, with the duration of such angling varied to achieve the amount of desired lateral movement. As the idler rollers 51 achieve the desired angle the nips 30 will induce lateral movement through a nip and paper dynamics 85 in accordance with an aspect of the disclosed technologies.
[0041] As yet a further alternative, independently pivoting idler rollers 51 can be angled differently in order to also induce or remove/prevent buckling of the sheet 5 . If the idler velocity vectors 12 of the two idler rollers 51 are angled slightly away from one another, it will remove/prevent buckling, whereas if they are angled toward one another it will induce buckling or relieve lateral tension on the sheet.
[0042] While the sheet 5 is still engaged by the nips 30 and at least one sensor 22 , 24 is still able to register a lateral position for the sheet, such sheet position information can be further correlated to the predesignated lateral position. By continually monitoring sheet position using the sensors 22 , 24 a closed-loop feedback regarding positional errors can be provided to the controller 70 . The controller 70 can thus continue to make adjustments to the idler angle(s) as needed. Further, by providing additional downstream sensors (not shown) measuring lateral and/or skew position, the closed-loop feedback can be provided to controller 70 over a greater length of the sheet in order to make continuous adjustments to the skew and/or lateral position while the sheet remains engaged by the nips 30 . Once the sheet is no longer engaged by the nips 30 , the idler angle(s) can be returned to zero or another default angle value for the next approaching sheet.
[0043] In addition to lateral position correction, other registration correction systems such as a differential drive system can be used to perform skew and/or process timing corrections. It should be understood that such skew, process and lateral adjustments can occur in any order or can occur at or near the same time. During any adjustment of skew, cross-process or process positioning or timing, any downstream nips are preferably opened to allow the sheet 5 to be adjusted more freely.
[0044] Often media handling assembly, and particularly printing systems, include more than one module or station. Accordingly, more than one registration system 100 as disclosed herein can be included in an overall media handling assembly. Further, it should be understood that in a modular system or a system that includes more than one registration system 100 , in accordance with the disclosed technologies herein, could detect sheet position and relay that information to a central processor for controlling registration, including lateral position and skew in the overall media handling assembly. Thus, if the sheet positional errors are too large for registration system 100 to correct, then correction can be achieved with the use one or more subsequent downstream registration systems 100 , for example in another module or station.
[0045] It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. | An assembly including two nip assemblies spaced apart along a first axis. Each nip assembly including a driven wheel and an idler roller. The driven wheel rotatably supported about the first axis. The idler cooperating with the driven wheel to engage a sheet. The idler rotatably supported about a second axis. The second axis being selectively moveable relative to the first axis. The selective movement between a first and second orientation while the sheet is moved along the transport path. In the first orientation the second axis extends parallel to the first axis. In the second orientation the second axis extends at an oblique angle to the first axis. The selective movement pivoting about a third axis extending through a centerline common to both the driven wheel and the idler. The selective movement of one of the two nip assemblies being independent from the selective movement of the other. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of a governor for a telephone dial. More particularly, this invention relates to an improved governor for a telephone dial which is composed of a liquid-sealed type of chamber.
2. Description of the Prior Art
The governor for a telephone dial used hitherto is composed of a series gears and springs. The convention governor for a telephone dial has been somewhat improved by the Korean Utility Model Registration No. 14,459 which was granted to the inventor, in which a certain dimension of cylindrical liquid-sealed chamber is provided immediately beneath the dial base, said liquid having a suitable viscosity, and rotating blades protruding from the rotating-axis of the telephone dial are rotated within the liquid upon dialing and it ensures that said axis can be returned back by the power of resistance of said liquid. Accordingly, in the comparison with the conventional gear-type timer governor for a telephone dial, such a liquid-sealed timer governor has the advantage that the governor can be simply constructed and readily manufactured. Moreover its durability and shock-resistance are excellent. Furthermore, in the liquid-sealed governor there are no gears used and therefore, noise due to gear-engaging can be prevented. However, since this prior liquid-sealed governor comprises a single cylindrical chamber in which a liquid is contained and blades which are fitted to the main rotating axis of the dial are positioned within the liquid, a uniformly accurate return back of the dial may not be achieved.
SUMMARY OF THE INVENTION
This invention relates thus to a governor for a telephone dial which is an improvement over said prior liquid-sealed governor. In other words, in this invention, the advantages and effects of use of a liquid-sealed chamber are maintained as they are, while instead of the rotating blade system, a piston system with a flexible valve is employed.
According to the invention, the liquid chamber is divided into two chambers, one being a right cylinder and the other being a rectangular hexahedron. These two chambers are directly connected to each other without any partitions therebetween. There is no limit in the dimensions of the two chambers. It is however preferred to divide the chambers for receiving a certain liquid such that the proportion of length thereof is of approximately 1:1.5.
There may be listed suitable liquids to use in this invention, such as water, vegetable, mineral or synthetic oils and the like. According to the invention, it is preferable to use a specific silicone oil.
It is the primary object of this invention to provide a governor for a telephone dial which has a liquid-sealed chamber for the time-controlling unit thereof.
It is another object of the invention to provide a governor for a telephone dial which allows the dial to be dialed without generating noises from the friction of gears.
Still another object of the invention is to provide such a governor which can be of a simple structure and can be easily manufactured.
These, together with other objects and advantages, will become apparent to those skilled in the art upon reading the details of construction and operation which are more fully set forth below, reference being made to the accompanying drawings forming a part of this application, wherein like numerals correspond to like parts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the governor for a telephone dial of the present invention, showing each of the sections thereof;
FIG. 2 is a cross-sectional view of the timer of the present invention cut along the line A--A of FIG. 1, showing the rearward position of the piston disposed within a liquid-sealed chamber;
FIG. 3 is the same view as shown in FIG. 2, except for showing the forward position of the piston;
FIG. 4 is a cross-sectional view cut along the line B--B of FIG. 3; and
FIG. 5 is a cross-sectional view cut along the line C--C of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and in particular to FIG. 1, there is shown a perspective view of the governor A according to the invention. The governor A is divided into two chambers 1 and 2, the latter being of a right cylinder and the former being of a rectangular hexahedron. The chamber 1 contains therein a rack 3 and a pinion 4, the rack 3 being engaged with the pinion 4 and can be moved to either side in rack guide recess 5 which is formed on one of the inner side walls of the chamber 1. The upper part of the governor A of the invention is connected to a conventional telephone dial unit which is composed of a dial 17 and a dial base 18 via a vertical axis 6 which is secured to the pinion 4. While, the lower end of said governor A is fixed to a gear in the terminal unit not shown.
The inner constructional view and the functional action of the governor A of this invention will be further illustrated in detail by FIG. 2 as set forth below.
In FIG. 2, the governor A, as already mentioned above, is divided into the chambers 1 and 2. The rack 3 is recessed in the recess 5 horizontally formed on a vertical side wall of the chamber such that it can be engaged with the pinion 4. The other chamber 2 is equiped with a piston 7 which is integrally connected to the rack 3 at one end thereof by means of a bolt 11. The piston 7 is provided with a flexible rubber plate acting as a valve, the peripheral edges of which are folded outwardly to a direction as shown in FIGS. 2 and 3. The plate 8 is integral secured to a circular compressive supporting plate 10 via bolts 11. The plate 8 also has a small hole 9 in the exact center portion thereof and through which a liquid can pass as described hereinafter. The piston 7 also has a small hole 12 which should be preferably positioned lower than the hole 9.
The above members are introduced and assembled through the open end of the governor body A and when the assembling of said members is completed, the open end is tightly and firmly secured by a closure 13 and then through an opening 14 a certain desired liquid 16 e.g. silicone oil introduced into the chamber 1 until this chamber 1 is filled up. Upon the completion of the introduction, the opening 14 is tightly and firmly closed by screw 15.
It will be now noted that the governor A for a telephone dial according to the invention is completely assembled.
According to an embodiment of this invention, the chamber 1 has a dimension of 25 mm×25 mm×50 mm, preferably 20 mm×20 mm×40 mm while the chamber 2 has a radius of 22 mm and a length of 28 mm. However, it should be understood that there are no limits in these dimensions. It is of importance that the pinion 3 must be positioned at the exact center portion of the inside of the timer body A. Further, it may be admitted to disposed an air tank of a flexible material in order to prevent the liquid from shrink.
The principle of the operation of the governor A according to the invention is based on the power of friction resistance against the movement of the piston 7 due to the liquid contained in the governor A.
At first, referring again to FIGS. 1 and 2, when the dial plate 17 is dialed, the axis 6 is rotated and thereby the spring 19 becomes compressively wound and at the same time the pinion 4 is rotated in the direction of the arrow R 1 , namely clockwise. The rotation of the pinion 4 permits the rack 3 to move in the direction of the arrow R 2 . As a consequence, the piston 7 also moves to the same direction R 2 and thus the liquid 16 in the side of the chamber 1 is compressed and moves into the side of the chamber 2 therefrom. At this time, the movement of the liquid 16 is established in the directions R 3 and R 4 through the hole 9 via the hole 12. In the movement of the liquid 16, the rubber plate 8 is bent forward by the friction power against the liquid. The folded portions 8' and 8' of the plate 8 can be more inwardly bent by the same friction power and hence a small portion of the liquid can be run into the chamber 2 via the holes 9 and 12 as well as the gap formed between the inner wall of the chamber and the folded peripheral edge of the rubber plate 8.
To the contrary, when the dial plate 17 is returned to the original position by means of the spring 19, the axis 6 is rotated to the right and thereby the pinion 3 moves to the left. Accordingly, the rack 4 moves to the left as shown in FIG. 3, and at this time, as the piston 7 also moves to the left, the liquid 16 in the chamber 2 is compressed and thereby it flows into the chamber 1 through the hole 12 via the hole 9. However, at that time, the liquid 16 can not pass the gap defined between the inner side wall and the folded peripheral portions 8' and 8' of the plate 8 because, as shown in FIG. 3, such a gap can not be formed in the case of this embodiment. In addition, in the case, since the positioning of the hole 12 is made in a crossed position to that of the hole 9, if the return of the dial plate 17 is interrupted by outer forces such as artificial forces, an alternation of the resilient force of the spring 19 or the like and thereby the pressure acting on the piston 7 is increased, the peripheral portion folded outwardly of the plate 8 is accessible to the front of the piston 7 and thus the passage of the liquid becomes narrower in size. Consequently, the piston 7 is subjected to a greater flow resistance and therefore, it can always be returned to its original position within a predetermined interval irrespective of outer forces.
As discussed in the foregoing, the rotation movement of the axis secured to the telephone dial plate makes it possible to change linearly reciprocal movement via a pinion and a rack. By this linearly reciprocal movement there is effected a reciprocal movement of the piston in the cylindrical chamber due to the power of resistance of the liquid against the piston.
The present invention has been shown and described in what is considered to be the most practical, and most preferred, embodiments. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to persons skilled in the art. | An improved governor device for a telephone dial which includes a rectangular hexahedral chamber provided with a rack engaged with a pinion and a cylindrical chamber provided with a piston secured to said rack at one end and having a valve system. The two chambers are filled up with a certain liquid such as silicone oil in order to afford a resistance to the piston. The piston can move either way upon dialing and at this time due to the resistance from the liquid the piston can reciprocate without any noise within a certain interval. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an information distribution system, more particularly relates to an information distribution system for distributing various types of information of newspapers, magazines, encyclopedias, security reports, etc. (hereinafter referred to as “content”) through the Internet or another open network to information receivers. This information distribution system can distribute vast amounts of content safely at a high speed.
[0003] 2. Description of the Related Art
[0004] In recent years, the spread of the Internet and other open networks (hereinafter referred to as “networks”) has led to an increase in electronic newspapers, electronic books, etc. prepared and distributed by information distributors. Homes and companies are now able to receive content such as electronic newspapers and electronic books on PCs and view them on-line or download them for viewing.
[0005] The information distribution systems of the related art, however, are configured to distribute one day's worth of a newspaper or one volume's worth of a book as it is as text data or image data, so the amount of the information transmitted becomes enormous. Accordingly, unless a broadband network or other high-speed communications line is used, it takes too a lot of time to distribute the information and therefore the systems are impractical. Further, even if using the high-speed communication lines, the amount of the information transmitted remains the same, so the problem arises of the distribution costs increasing in proportion to the amount of information transmitted. Further, the problem arises of the need to lay new high-speed communication lines.
[0006] Further, even if high-speed communication lines are already laid, the problem of the communication speed of the lines between the high-speed line network and the PCs remains.
SUMMARY OF THE INVENTION
[0007] An object of the present invention is to provide an information distribution system transmitting the information to be distributed converted into colors, color values, or color digital values so as to minimize the amount of information transmitted.
[0008] According to the present invention, there is provided an information distribution system for distributing newspaper, magazine, book, encyclopedia, security report, and other content provided by an information distributor to an information receiver through an open network such as the Internet. The information distribution system transmits the content to be distributed converted to colors, color values, or color digital values.
[0009] Preferably, the information distribution system divides the content to be distributed into a plurality of objects and transmits the objects converted to the colors, color values, or color digital values.
[0010] More preferably, the information distribution system divides the content into objects consisting of at least one of individual letters; entries in dictionaries such as words, phrases, personal names, place names, specialized terms, and foreign words; and word strings appearing in the content.
[0011] Alternatively or more preferably, the information distribution system provides a color conversion table for converting the content or objects to be transmitted to the colors, color values, or color digital values at the information distributor side.
[0012] Still more preferably, the information distribution system provides a color reversion table for converting back the transmitted colors, color values, or color digital values to the content or objects at the information receiver side.
[0013] Further, still more preferably, the information distribution system distributes the color reversion table to the information receiver side through the open network.
[0014] More preferably, the information distribution system outputs the content or objects converted back from the colors, color values, or color digital values by the color reversion table by display, printing, or sound.
[0015] Alternatively or still more preferably, the information distribution system makes the correspondence between the content or objects and the colors, color values, or color digital values in the color conversion table and color reversion table freely changeable.
[0016] Alternatively or still more preferably, the information distribution system makes the correspondence between the content or objects and the colors, color values, or color digital values in the color conversion table and color reversion table assignable to a hierarchical structure.
[0017] Preferably, the information distribution system distributes color reversion table designation information designating a color reversion table for use when converting back the colors, color values, or color digital values to the content or objects to information receivers before or simultaneously with transmitting the colors, color values, or color digital values.
[0018] More preferably, the color reversion table designation information is authorized to be distributed to information receivers specifically qualified by concluding a distribution agreement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] These and other objects and features of the present invention will become clearer from the following description of the preferred embodiments given with reference to the attached drawings, wherein:
[0020] [0020]FIG. 1 is a flow chart of production of a newspaper;
[0021] [0021]FIG. 2 is a view of the configuration of a newspaper information distribution system;
[0022] [0022]FIG. 3 is a detailed view of the configuration of the system at the information distributor side;
[0023] [0023]FIG. 4 is a view of an example of a color conversion table and color reversion table;
[0024] [0024]FIG. 5 is a view of another example of a color conversion table and color reversion table;
[0025] [0025]FIG. 6 is a view of an actual example of analysis of composition; and
[0026] [0026]FIG. 7 is a detailed view of the configuration of the system at the information receiver side.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Preferred embodiments of the present invention will be described in detail below while referring to the attached figures. The configurations, relative arrangements, etc. explained in the embodiments are just explained schematically to an extent enabling understanding of the present invention. Accordingly, the present invention is not limited to the embodiments described below and may be changed in various ways to an extent not departing from the scope of the technical idea indicated in the claims. In particular, importantly, in the following explanation, reference is made to an English language newspaper information distribution system for facilitating understanding of the invention, but the invention is not limited to the same and in fact was originally designed for and may be more optimally suited to languages using more complicated writing systems employing combinations of phonetic syllabary and ideographs such as Japanese and therefore requiring much more data to encode and transmit.
[0028] [0028]FIG. 1 is a flow chart of the production of a newspaper. Step 1 consists of the collection and storage of articles and images. This step 1 collects and stores articles and images sent from news sites, branch offices, other news agencies, etc.
[0029] Step 2 consists of the editing of the articles and images. This step 2 selects and edits the suitable articles and images to be carried in the newspaper from the large number of articles and images collected and stored at step 1 .
[0030] Step 3 consists of the layout of the articles and images. This step 3 attaches headlines etc. to the articles and images edited at step 2 and lays out the pages.
[0031] Step 4 consists of the printing. This step 4 uses film of the laid out copy produced at step 3 to print the newspaper by a printing press.
[0032] Step 5 consists of the shipping step. This step 5 divides the newspapers printed at step 4 for the different destinations, then ships them to newspaper delivery centers.
[0033] Step 6 consists of the delivery step. This step 6 delivers the newspapers from the newspaper delivery centers to the different homes. Steps 1 to 6 show the process of newspaper production by paper as in the past.
[0034] Step 7 consists of the conversion of the newspaper to electronic data. In recent years, more and more electronic versions of newspapers have been produced. This step 7 delivers the electronic data of the newspaper to terminals 9 through the network 8 . The information distribution system according to the present invention is used for distribution of newspaper information from step 7 on.
[0035] [0035]FIG. 2 is a view of the configuration of a newspaper information distribution system. In this newspaper information distribution system, reference numeral 10 shows the system at the information distributor side, while reference numeral 11 shows the system at the information receiver side. The information distributor side system 10 corresponds to step 7 , while the information receiver side system 11 corresponds to any one of the above terminals 9 .
[0036] The information distributor side system 10 converts the newspaper article original data 12 to converted color data 13 by a color conversion table 13 . Details will be explained later. Further, the information receiver side system 11 converts the converted color data 14 delivered through the network 8 back to the reproduced newspaper article data 16 by a color reversion table 15 . The reproduced newspaper article data 16 is output as an image by a display 17 , output as speech or sound by a speaker 18 , or output as papers by a printer 19 . Further, it is output for recording and storage in a storage device 20 . These types of output may be performed independently or freely combined.
[0037] The color conversion table 13 encodes the newspaper article original data 12 to the converted color data 14 . The color reversion table 15 decodes the newspaper article original data 12 which had been encoded to the converted color data 14 by the color conversion table 13 to the reproduced newspaper article original data 16 . The color reversion table 15 is provided at the information receiver side system 11 by transmission over the network 8 or the mail.
[0038] [0038]FIG. 3 shows the detailed configuration of the information distributor side system 10 . In FIG. 3, reference numeral 21 shows a newspaper article original data input unit. The newspaper article original data input unit 21 may receive as input the newspaper article original data 12 .
[0039] Reference numeral 22 is an original data composition analysis unit. The original data composition analysis unit 22 analyzes the sentence structure of the newspaper article original data 12 input to the newspaper article original data input unit 21 and breaks it down into individual letters; words, phrases, personal names, place names, specialized terms, foreign words, and other entries in various types of dictionaries; or word strings frequently appearing in the newspaper article original data 12 . Note that the individual letters broken down by the original data composition analysis unit 22 are letters for each type of word such as verbs, adjectives, adverbs, etc. Further, verbs with changes in form, adjectives, adverbs, etc. are broken down for each form of use.
[0040] Reference numeral 23 is an object automatic extraction unit. The object automatic extraction unit 23 extracts the individual letters, entries in various dictionaries, or word strings broken down by the original data composition analysis unit 22 as objects.
[0041] Reference numeral 24 is an object/color conversion unit. The object/color conversion unit 24 refers to the color conversion table 13 prepared in advance to convert the objects extracted by the object automatic extraction unit 23 to colors 14 a, color values 14 b, or color digital values 14 c as converted color data 14 corresponding to the objects. Details of the colors 14 a, color values 14 b, and color digital values 14 c will be explained later. Note that in this embodiment, the explanation was given of a configuration preparing a color conversion table 13 in advance, but the present invention is not limited to this. A color conversion table 13 may be automatically generated each time a new object is extracted by the object automatic extraction unit 23 by newly assigning a color 14 a, color value 14 b, or color digital value 14 c by using a known automatic dictionary preparation method.
[0042] Reference numeral 25 is a converted color data output unit. The converted color data output unit 25 selectively outputs colors 14 a, color values 14 b, or color digital values 14 c obtained by conversion at the object/color conversion unit 24 . The selectively output colors 14 a, color values 14 b, or color digital values 14 c are transmitted to the information receiver side system 11 through the network 8 .
[0043] [0043]FIG. 4 shows an example of a color conversion table 13 and color reversion table 15 used in a newspaper information distribution system. In the conversion or reversion table, information is arranged alphabetically in two levels. In the figure, reference numeral 26 shows the rows of individual letters as a first level. Each row 26 is divided into objects 27 as a second level. Note that FIG. 4 shows part of a color conversion table 13 and color reversion table 15 , in particular shows nouns with no changes in form.
[0044] Each object 27 may be expressed by colors 14 a each comprised of two specific colors. Specifically, one object 27 is expressed by a minimum of two pixels. That is, colors 14 a are output as the converted color data 14 from the converted color data output unit 25 by the method of using the object/color conversion unit 24 read printed matter consisting of sets of color dots of one pixel per level each and then output the colors.
[0045] Assuming that printed matter consisting of sets of color dots is printed at a density of 1200 dpi, 1.44 million dots are printed per square inch. That is, in the case of the present embodiment expressing one object by two dots, it is possible to store an extremely vast amount of information of 720,000 objects on one square inch of paper. Further, if converting the printed matter to A4 size paper, it is possible to store information of about 70 million objects or as much as 97 times the above figure. If the number of individual letters used per day of a newspaper were 400,000 letters and average number of letters for one object were three, it would be possible to store about 1.4 years' worth of newspaper articles on one sheet of A4 size paper. Note that if only one level was used in the color conversion table 13 and color reversion table 15 , the amount of information stored would double of course.
[0046] Each object 27 may also be expressed by color values 14 b each comprised of a total of four freely assigned numerals, that is, two numerals for each level. That is, the color values 14 b are output as the converted color data 14 from the converted color data output unit 25 by the method of having the object/color conversion unit 24 directly output four numerals. Note that the number of numerals of each level is not limited to two. It is possible to freely set the number in accordance with the size of the color conversion table 13 and color reversion table 15 .
[0047] Each object 27 may also be expressed by color digital values 14 c each comprised of a total of 24 bits for each level, that is, a total of 48 bits of RGB data. That is, the color digital values 14 c are output as the converted color data 14 by the method of having the object/color conversion unit 24 directly output 48 bits of data. Note that the number of bits for each layer is not limited to 24 bits and can be set to any number in accordance with the size of the color conversion table 13 and color reversion table 15 .
[0048] [0048]FIG. 5 shows a table of verbs with changes in form in the table shown in FIG. 4 as an example of the color conversion table 13 and color reversion table 15 . The structure of the table in this example is the same as the example shown in FIG. 4, so the same reference numerals are assigned and detailed explanations are omitted.
[0049] Next, the color conversion tables 13 shown in FIG. 4 and FIG. 5 will be used to explain the processing in the original data composition analysis unit 22 and the object automatic extraction unit 23 . As one example, the case of analyzing newspaper article original data 12 comprised of the 34 letters of “APPLY TO BUREAU OF HOUSING FOR APARTMENT” input to the newspaper article original data input unit 21 by the original data composition analysis unit 22 will be explained using FIG. 6. As shown in FIG. 6, the original “APPLY TO BUREAU OF HOUSING FOR APARTMENT” is broken down by the original data composition analysis unit 22 , whereby five objects of object 1 to object 5 are extracted by the object automatic extraction unit 23 . Due to this, the 34 letters of the original are converted to five sets of, that is, ten, color dots and expressed by an average of 6.8 letters' worth of data per set. Note that in FIG. 6, object 2 and object 4 are particles. If preparing the color conversion table 13 in a form joining them with the previous objects, that is, the object 2 with the object 1 and the object 4 with the object 3 , it becomes possible to express the 34 letters by three sets of, that is, six, color dots.
[0050] [0050]FIG. 7 is a detailed view of the configuration of the information receiver side system 11 . In FIG. 7, reference numeral 28 shows the converted color data input unit. The converted color data input unit 28 receives as input the converted color data 14 transmitted through the network 8 .
[0051] Reference numeral 29 shows a color/object conversion unit. The color/object conversion unit 29 converts the converted color data 13 input to the converted color data input unit 28 to objects corresponding to the converted color data 14 by referring to the color reversion table 15 distributed through the network 8 or mailed in advance. Here, when using the colors 14 a as the converted color data 14 , it is also possible to output the printed matter comprised of sets of color dots before conversion to objects, then convert the printed matter to objects corresponding to the colors 14 a by the color/object conversion unit 29 .
[0052] Reference numeral 30 shows an object automatic editing unit. The object automatic editing unit 30 recomposes the objects converted at the color/object conversion unit 29 to the sentences of the newspaper article original data 12 .
[0053] Reference numeral 31 shows a newspaper article data reproduction unit. This newspaper article data reproduction unit 31 divides the sentences recomposed at the object automatic editing unit 30 into headlines, text, etc. in the same way as the conventional layout step 3 and reproduces the paper layout.
[0054] Reference numeral 32 shows a newspaper article data output unit. This newspaper article data output unit 32 outputs the reproduced newspaper article data 16 reproduced at the newspaper article data reproduction unit 31 by a display 17 , speaker 18 , printer 19 , or storage device 20 alone or in combination.
[0055] Based on the above configuration, the newspaper information is distributed upon instruction of the information distributor or request of the information receiver. Even when using color digital values 14 c comprised of two levels, the converted color data 14 transmitted through the network 8 becomes very short in length. In the case of a Japanese language system, the converted color data 14 transmitted through the network 8 becomes a maximum of three Japanese kanji ideographs' (48 bits') worth of data in length. The longer the corresponding objects 27 , the more easily it is to deliver newspaper information with a high compression rate. In particular, in the case of use of the color conversion table 13 and the color reversion table 15 as shown in FIG. 4 and FIG. 5, the compression rate becomes remarkably high.
[0056] Further, in the present embodiment, the explanation was given assuming a fixed correspondence among the objects 27 and colors 14 a, color values 14 b, and color digital values 14 c. That is, as shown in FIG. 4 and FIG. 5, objects 2 and colors 14 a, color values 14 b, and color digital values 14 c were converted back and forth in the same row. When, for example, converting back and forth between objects 27 and colors 14 a, color values 14 b, and color digital values 14 c in different lines, however, it is also possible to transmit correspondence changing information to the information receivers simultaneously with the distribution of information or in advance and make the correspondence freely changeable.
[0057] Due to this, it is possible to not transmit correspondence changing information to information receivers other than specific receivers whose distribution agreements remain valid and therefore are qualified to receive it. Therefore, information receivers whose agreements for information distribution have expired cannot correctly reproduce the newspaper information, and illegitimate viewing of newspaper information can be prevented.
[0058] In the present embodiment, the color conversion table 13 and the color reversion table 15 were explained as single tables, but it is also possible to prepare a plurality of color conversion tables 13 and distribute a plurality of color reversion tables 15 corresponding to them. In this case, it is sufficient to transmit color reversion table designating information indicating which color reversion table to use at the time of distribution of information simultaneous with the distribution of information or in advance.
[0059] While the invention has been described with reference to a specific embodiment chosen for purpose of illustration, the present invention is not limited to the newspaper information distribution system in the embodiment. It may also be applied to an information distribution system for various content including vast amounts of information such as of magazines, books, encyclopedias, security reports and the like. It should be apparent that numerous modifications could be made thereto by those skilled in the art without departing from the basic concept and scope of the invention.
[0060] According to the present invention, it is possible to transmit the tremendous amounts of data about various content of newspapers, magazines, books, encyclopedias, security reports, etc. in a radically compressed form on the Internet or another open network. Therefore, it is possible to distribute information at a high speed even by a conventional communications line rather than a high-speed communications line of a broadband network etc. The data transmitted over the network is converted color data which in itself is not data of any meaning, so it is possible to distribute information safely without leakage of the content of the information to a third party. Further, it is possible to easily manage the color reversion table distributed to the information receivers.
[0061] The present disclosure relates to subject matter contained in Japanese Patent Application No. 2001-158864, filed on May 28, 2001, the disclosure of which is expressly incorporated herein by reference in its entirety. | An information distribution system configured to deliver various types of content provided by an information distributor to information receivers through a network and transmitting the content to be distributed converted to colors, color values, or color digital values. By converting the content to colors, color values, or color digital values, it is possible to reduce the amount of information transmitted. Due to this, it becomes possible to shorten the time required for distribution of content and to improve practicality. Further, it becomes possible to reduce the distribution costs. | 7 |
PRIORITY
This application claims the benefit of U.S. Provisional Application Ser. No. 61/511,502, filed on Jul. 25, 2011, which is hereby incorporated by reference in its entirety herein.
FIELD
The present invention generally relates to a PEEK spacer for use in the spine. More particularly, the present invention relates to a PEEK spacer configured to fit through Kambin's Triangle and expand upon insertion.
SUMMARY
It is desirable to spare the facet joint when placing spacers for intervertebral stabilization, support and fusion. There is a need for a PEEK spacer that is small enough to fit through Kambin's Triangle, yet able to expand upon insertion to fully support and/or stabilize the intervertebral space. According to one embodiment of the present invention, the PEEK spacer may be placed via a facet sparing, transforaminal approach. In an embodiment, the PEEK spacer of the present invention may be placed through a minimally invasive operative access. In another embodiment, the PEEK spacer of the present invention may be placed through a percutaneous operative access.
According to one embodiment of the present invention, the PEEK spacer may be sized to be placed through a 15 mm×6 mm area at the L4-L5 vertebra. According to another aspect, the PEEK spacer of the present invention may be placed at any other desired vertebral level. In another embodiment of the present invention, the PEEK spacer may contain bone graft. According to one aspect, the PEEK spacer of the present invention may include an opening for bone graft insertion. In yet another embodiment of the present invention, the PEEK spacer may be configured to allow bony ingrowth through the spacer. According to one aspect of the present invention, the PEEK spacer may include an anti-backout feature.
In yet another embodiment, the PEEK spacer of the present invention may be configured to rotate from a first insertion position to a second implanted position. In an embodiment of the present invention, the PEEK spacer may be inserted in a first collapsed geometry and expanded to a second geometry after placement. In one embodiment of the present invention, the PEEK spacer may include arms, wings or other expandable members. In an embodiment of the present invention, expandable members may be solid such that fill material cannot escape back out of the entrance hole. In another embodiment expandable members may include slots or slits to allow bone ingrowth.
According to one embodiment of the present invention, the PEEK spacer may include a PEEK film configured to maintain the spacer in a collapsed geometry. In one aspect of the present invention, an expansion tool may be configured to pierce the PEEK film allowing the arms, wings or other expandable members to expand.
In yet another embodiment, the PEEK spacer of the present invention may be expanded using a screw or other suitable mechanism. According to another aspect of the present invention, the PEEK spacer may employ a ramp mechanism for expansion.
In an embodiment of the present invention, the PEEK spacer may include a central strut having a diversion configured to split a stream of bone or other fill material directing the fill material to both sides of the strut.
In yet another embodiment of the present invention, the arms, wings or other expandable members may be pivotally or otherwise movably attached to the spacer body. According to one aspect of the present invention, the PEEK spacer may include an asymmetrical taper along the implant width. In another embodiment, the PEEK spacer of the present invention may include lateral support features to help the implant stay upright when the disc space is subjected to shear forces.
According to one embodiment, a mesh container may be used with the PEEK spacer to contain fill material.
The detailed technology and preferred embodiments implemented for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention. It is understood that the features mentioned hereinbefore and those to be commented on hereinafter may be used not only in the specified combinations, but also in other combinations or in isolation, without departing from the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a perspective view of an embodiment of the present invention.
FIG. 2 depicts a perspective view of an embodiment of the present invention.
FIG. 3 depicts a perspective view of an embodiment of the present invention in an expanded configuration.
FIG. 4 depicts a side perspective view of an embodiment of the present invention in an expanded configuration.
FIG. 5 depicts a perspective view of an embodiment of the present invention.
FIG. 6 depicts a perspective view of an embodiment of the present invention.
FIG. 7 depicts a perspective view of an embodiment of the present invention.
FIG. 8 depicts a perspective view of an embodiment of the present invention.
FIG. 9 depicts a perspective view of an embodiment of the present invention.
FIG. 10 depicts a perspective view of an embodiment of the present invention.
FIG. 11 depicts a perspective view of an embodiment of the present invention.
FIG. 12 depicts a perspective view of an embodiment of the present invention.
FIG. 13 depicts a perspective view of an embodiment of the present invention.
FIG. 14 depicts a perspective view of an embodiment of the present invention.
FIG. 15 depicts a perspective view of an embodiment of the present invention.
FIG. 16 depicts a perspective view of an embodiment of the present invention.
FIG. 17 depicts a perspective view of an embodiment of the present invention.
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular example embodiments described. On the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. For illustrative purposes, cross-hatching, dashing or shading in the figures is provided to demonstrate sealed portions and/or integrated regions or devices for the package.
DETAILED DESCRIPTION
In the following descriptions, the present invention will be explained with reference to example embodiments thereof. However, these embodiments are not intended to limit the present invention to any specific example, embodiment, environment, applications or particular implementations described in these embodiments. Therefore, description of these embodiments is only for purpose of illustration rather than to limit the present invention. It should be appreciated that, in the following embodiments and the attached drawings, elements unrelated to the present invention are omitted from depiction; and dimensional relationships among individual elements in the attached drawings are illustrated only for ease of understanding, but not to limit the actual scale.
As shown in FIGS. 1-5 , an embodiment of the present invention may include spacer body 12 and expandable members 14 a and 14 b . According to an embodiment of the present invention, the spacer of the present invention may be inserted into an intervertebral disc space while sparing the facet joint. The spacer of the present invention is sized to fit through Kambin's triangle via a far lateral surgical approach thus sparing the facet joint.
Expandable members 14 a and 14 b may be movably attached to spacer body 12 . Peek or other suitable film 16 may be wrapped around spacer 10 such that spacer 10 remains in a collapsed geometry during insertion. In another embodiment, any thin thread, woven tape or other suitable material may be wrapped around spacer 10 such that spacer 10 remains in a collapsed geometry during insertion.
After placement of spacer 10 is complete, expansion tool 18 may be inserted through channels 20 a and 20 b such that tool 18 pierces film 16 allowing spacer 10 to be expanded into its expanded configuration. In an embodiment, film 16 may be pulled to expand spacer 10 . Spacer 10 may be rotated once placed. Bone graft or other desired bone substitute or fill material, may be inserted through an opening in spacer 10 .
FIG. 6 depicts another embodiment of spacer 30 having spacer body 32 and expandable member 34 . Opening 36 may accept the introduction of fill material.
FIG. 7 depicts an alternate embodiment of spacer 40 having spacer body 42 and expandable members 44 a and 44 b.
FIG. 8 depicts another embodiment of spacer 50 having spacer body 52 and expandable members 54 a and 54 b.
FIG. 9 depicts an embodiment of spacer 60 having spacer body 62 and expandable members 64 a and 64 b.
FIG. 10 depicts an embodiment of spacer 70 having spacer body 72 , wherein only one expandable member 74 a is shown to illustrate ramp 76 .
FIG. 11 depicts spacer 80 having spacer body 82 and expandable members 84 a and 84 b . Spacer 80 is shown in the expanded position illustrating expansion tool 86 .
FIG. 12 depicts an alternate embodiment of spacer 90 having spacer body 92 and expandable members 94 a and 94 b . Opening 96 may accept the introduction of fill material.
FIG. 13 depicts another embodiment of spacer 100 having spacer body 102 and an expandable member 104 . Opening 106 may accept the introduction of fill material.
FIG. 14 depicts an alternate embodiment of spacer 110 having expandable members 112 , 114 , 116 , and 118 . Expandable members 112 , 114 , 116 , and 118 are movably connected to one another such that spacer 110 may be inserted in a collapsed geometry and opened to an expanded geometry after placement.
FIG. 15 depicts spacer 120 having spacer body 122 and expandable members 124 a and 124 b . Spacer 120 may be opened to an expanded configuration by drawing back distal ramp 128 back with a screw or other suitable mechanism.
FIG. 16 depicts an embodiment of spacer 130 having spacer body 132 and expandable member 134 .
FIG. 17 depicts an embodiment of spacer 140 having spacer body 142 and expandable members 144 a and 144 b . Any of the embodiments of the present invention may include expandable members which may be expanded from a first closed position to a second open position, or any position therebetween, in a variety of ways. According to one aspect of the present invention, expandable members may be expanded by a mechanical expansion tool such as for example, a paddle or rod. In such an example embodiment, a mechanical expansion tool may be inserted through an opening in spacer body 142 and in between expandable members 144 a and 144 b . A mechanical expansion tool may then be actuated to move expandable members from a first closed position to a second open position. Expandable members 144 a and 144 b may be partially opened, fully opened or opened to any position therebetween.
In another embodiment, expandable members may be expanded by the introduction of a balloon. In such an example embodiment, a deflated balloon may be inserted through an opening in spacer body 142 and in between expandable members 144 a and 144 b . The balloon may then be inflated, moving expandable members 144 a and 144 b from a first closed position to a second open position. Expandable members 144 a and 144 b may be partially opened, fully opened or opened to any position therebetween.
In yet another embodiment, expandable members may be expanded by the introduction of fill material, such as for example bone graft, bone substitute or any biocompatible fill material or any combination thereof. Expandable members may be partially opened, fully opened or any opened to any position therebetween.
Although the description of the invention generally contemplates placing the PEEK spacer of the present invention in the intervertebral space, the PEEK spacer of the present invention may also be placed within a vertebral body.
Although the description of the invention generally contemplates using spacer comprised of PEEK, any biocompatible material or combination thereof may be used in the composition of the spacer.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is, therefore, desired that the present embodiment be considered in all respects as illustrative and not restrictive. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto. | A PEEK spacer for use in the spine is disclosed. The PEEK spacer may be configured to fit through Kambin's Triangle and expand upon insertion. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 08/494,533 filed Jun. 22, 1995, now U.S. Pat. No. 5,676,685, filed Jun. 22, 1995.
BACKGROUND OF THE INVENTION
The present invention relates to the type of endoprosthesis devices commonly known as stents. More particularly, it relates to stents of the type intended for temporary implantation within a body vessel, duct, urinary tract or the like.
Stents are usually placed or implanted within a blood vessel for example for treating stenoses, strictures or aneurysms. The purpose is to reinforce collapsing, partially occluded, weakened or abnormally dilated sections of a vessel or duct. For example, one common procedure in partially occluded blood vessels is to first open the region in the vessel with a balloon catheter and then place a stent in a position that bridges that region of the vessel.
One technique for implanting a stent uses a balloon catheter to position the stent within a vessel. Once the stent is properly positioned, the balloon is withdrawn, leaving the stent in place. In some cases, the balloon may be inflated during placement to press the stent against the inner wall of the vessel before being withdrawn.
SUMMARY OF THE INVENTION
The improved temporary stent of the invention is comprised of two main elements, one being a two-layer biodegradable/bioabsorbable (bio-materials herein generally) element and the other being a reinforcing wire, core body or a like element which may be removed at some time following implantation of the stent, leaving the "bio" element to gradually disappear on its own over time.
Typically, the reinforcing element core body will comprise a core of coil spring shape to provide radial support from within the stent while allowing for removal of the core by merely pulling it out through a guiding catheter or the like.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a partly schematic illustration of a first embodiment of a temporary stent according to the invention after emplacement, the stent size being somewhat exaggerated for descriptive purposes;
FIG. 2 is a cross-section view taken along line 2--2 of FIG. 1;
FIG. 3 is a simplified sectional view showing the coil of FIG. 1 in relation to an artery;
FIG. 3a is a simplified sectional view showing the coil of FIG. 1 in relation to an artery which contains an aneurysm;
FIG. 4 is a cross-section of an alternate embodiment of the stent of FIG. 1;
FIG. 5 is a view similar to that of FIG. 1 showing another embodiment of the invention, including a double coil or helix reinforcement element which may be fused for removal;
FIG. 6 is a sectional view taken along line 6--6 of FIG. 5 showing the core wire separating and retracting after being heated by electrical energy;
FIG. 7 is a showing of a triple reinforcement element which may be used in the invention;
FIG. 8 is another embodiment of the invention in which the reinforcing coil element is placed within a tubular shell of the bio element;
FIG. 9 is a cross-section taken along line 9--9 of FIG. 8;
FIG. 10 is yet another embodiment of the invention including aspects of FIG. 3 and FIG. 7;
FIG. 11 is still another embodiment of the invention incorporating a balloon around the reinforcement element for facilitating removal;
FIG. 12 is a cross-section taken along line 12--12 of FIG. 11;
FIG. 13 is another embodiment of the invention in which the reinforcing coil element and its bio layer are contained within a cylindrical tube of biomaterial; and
FIG. 14 is a cross-section taken along line 14--14 of FIG. 13.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1, 2 and 3 and the embodiment shown therein, assume that stent 10 has been initially placed within a vessel 11 (see FIG. 3) or the like. Stent 10 is comprised of a wire coil 12 enclosed within a sheath or coating indicated at 14 of biodegradable/bioabsorbable material. Coil 12 may be tightly wound or coiled around a catheter, assuming a small diameter for placement. Upon release the springlike material causes it to self-expand. On the other hand, it may be deformable and expandable mechanically as by a balloon inside the stent. Both approaches are known in the art.
Coating 14 is preferably made up of two layers 16 and 18, respectively as best seen in FIG. 2. Although both layers 16 and 18 are a "bio" material, layer 18 is also of a material selected to soften or even liquify at some predetermined safe elevated temperature that is above body temperature but below about 60° C. so as to be safe. Thus, upon being exposed to such a temperature, layer 18 softens to release core wire 12 so that it can be pulled through guiding catheter 20 and removed from the emplacement, leaving only the bio material 14 in place. Removal of core wire 12 will of course be accomplished at such time as the stent has served its temporary purpose.
Core wire 12 may for example be metal such as stainless steel or gold or other relatively pliable non-toxic metals and alloys that do not degrade during the time of implantation or are not subject to severe degradation (corrosion) under the influence of an electric current. Such metals include but are not limited to platinum, platinum-iridium alloys, copper alloys, with tin or titanium, nickel-chrome-cobalt alloys, and nickel-titanium alloys. Such metal cores may for example be between about 0.005 to 0.008 inches in diameter. Of course, the diameter could vary depending on lumen size and degree of support needed. The core need not be metal and may for example be of a polymeric material such as an elastomer, a polyester or the like. In general, any material acceptable to the body and capable of being formed into an elongate filament-like configuration, which can be used to transfer heat and which can be configured for temporary reinforcement purposes and still pulled loose for removal will be satisfactory for the purposes of this invention. The filament may be metal, inorganic fibers or organic polymers.
Polymeric materials and composites that can be formed into elongate filaments and which can be configured for providing reinforcement include polyethylene-terephthalate (PET), polyimides, high durometer polyurethanes, polyacrylontride, high strength polyethylene and polyamides. High strength fibers, such as boron, aluminum oxide, aluminum-boria-silica, silicon nitride and graphite-epoxide may be used. Very thin (25-50 micrometer diameter) strands of flexible, high strength material, such as liquid crystalline materials when combined with materials that soften to provide a mechanism such that the softer material maybe removed without breaking or cracking, may be used. Thus, conductive high strength graphite fiber may be combined with a low durometer polyurethane to form the core 12.
Materials that are not normally conductive may be made so as by applying thin flexible coatings of gold by ion vapor depositions or the like or by incorporating metallic particles into extrusions of such materials. Core 12 can be made of a composite so constructed that a normally non-conductive supportive portion may include a central conducting metallic wire or soft flexible metallic wires or graphite fibers, which are conductive, woven into strands with a supporting nonconductive element.
As to the "bio" material 14, layer 16 may be any biodegradable or bioabsorbable material such as for example: polycaprolactone, polylactic acid, polylactic acid-glycolic acid, polyurethane or other "bio" materials either alone or in combination with other materials which might be used as the vessel wall contacting element of the stent. Preferably, the material of layer 16 will not be substantially affected by the heat applied to the stent. Such materials include DOW2363 polyurethane (DOW-Midland, Mich.), MDX 4210 silicone rubber and polyvalerolactone.
This layer may also include quantities of such materials as: anti-thrombotic, anti-platelet, vasodialators, anti-proliferative agents and more specifically, Heparin, Hirudin, Hirulog (an anti-thrombotic produced by Biogen, Inc. of Cambridge, Mass. 02142), Etritinate (an anti-proliferative, generic for Tegison and the like supplied by Rache Dermatologist of Nutly, N.J. 07110), Freskolin (an antithrombotic and vasodilator) and the like.
Layer 18, as already indicated, is also a "bio" material but it has the property of softening or liquefying at a safe elevated temperature above body temperature, i.e., between about 45-60° C. Polyurethane is an example of such a material. Polyurethanes that have about 40 mole percent of soft segment comprised of polyethers can be formulated to soften in the desired temperature ranges. Polycaprolactone is another example. Also, polyesters such as poly-1-lactides poly-1-glycolides and polybutene terephthalates may be used. Copolymers such as expoxides and polyamides may also be formulated with softening segments of silicone rubber. Nylon 6/6 with about 10 to 30 volume percent of polymethylsiloxane as a copolymer may be used. Polyaliphatics such as polyethylene may be combined with plasticizers such as dibutyl adipate or polyester adipate or glycerol derivatives may be tailored to soften in the safe temperature range. Polymeric materials such as low molecular weight polyethylene having a MW between about 1000 to 50,000 may be used. Copolymers of polyethylene with polyamides may be formulated to soften or become fluid. Polycaprolactone may be used as layer 18. Polyethylene oxide (PEO) of molecular weight 1000 to about 10,000 will liquify in the desired temperature range as well composites of PE and PEO in that molecular weight range. These materials can be heated by convection.
The thickness of these layers 16 and 18 may vary depending on use and material but will generally be between 10 to 100 micrometers in thickness and preferably about 20-40 micrometers. The criteria for thickness rests in the ability of the layer 16 to support the vessel when layer 18 is softened or the like.
As shown in FIG. 1, the temporary stent 10 upon being implanted in a body may continue to be attached to a long lead portion means 12a extending through guiding catheter 20 until time for removal. On the other hand, it may be detached and reattached at time of removal by means of a suitable connector (not shown). When removal is desired the power source 22, properly connected for operation to lead 12a through elements 24 and 26, is activated and core wire 12 heats up to cause softening of layer 18 upon which the proximal end of lead 12a may be pulled to remove core wire 12 from the stent.
Layer 18 is preferably heated by electrical heating, although laser radio frequency (RF) or any other energy source may be used. In the case of FIG. 1, electrical resistance heating is used by means of a power source which may be connected to electrically conductive core wire 12 by means of an electric selector switch 24 and a connector plug 26. Layer 18 is positioned functionally in the stent so as to be disposed between layer 16 and core 12. When it "releases" upon softening, due to heating of core 12, core 12 may be readily pulled out with minimal disturbance of layer 16, leaving layer 16 in place. Some of layer 18 biomaterial may be removed with core 12 and some may remain in place. More specifically, when layer 18 releases upon softening, core 12 is readily pulled out. Layer 18 remains in place, or if it liquifies, portions of layer 18 may remain attached to core 12 and resolidify upon reducing energy input. If layer 18 is essentially water insoluble, such as low molecular weight PE, it will not dissolve into the blood should that occur. If the layer is not melted but only softened, then core 12 will slip through layer 18, leaving it totally in place.
Generally, the loop or coil structure is preferred for placement due to the convenience of its easy removal on being pulled out. However, other configurations, particularly other radial configurations which may readily be pulled loose, will become apparent to those familiar with this art. Also, although the core is shown as a typical round in cross-section wire, there is no reason that other cross-section configurations such as flat and the like could not be used, the former however is presently preferred.
Thus, it can be seen that in one embodiment of the invention, a coated coiled stent is placed and remains in physical contact with a transcutaneous insertion point by means of a wire core or the like. Upon application of heating energy to the stent through the core, the coating or a portion thereof is allowed to remain in place while the core is removed. The core not only functions as a reinforcement element but as an energy conduit. The outer layer 16 or coating is preferably not to be significantly affected by the heat whereas the middle layer 18 is softened or melted, enabling removal of the core portion 12.
As shown in FIGS. 3, 8 and 10, during typical procedures the damaged vessel or duct wall is collapsed in the lumen 17. The exception would be in the case of aneurysm repair, in which case there might be some outward bulging of the vessel wall as shown in FIG. 3a.
Referring now to FIG. 4, another version of stent construction is shown in which core wire 12 is only partially enclosed or encapsulated by element 14 (layers 16-18). In effect, in this embodiment core 12 lies in a groove in layer 18. When wound into a coil or similar configuration, this structure is positioned so as to present layer 16 to the vessel wall with the core 12 being disposed toward the interior. It may be removed in the same fashion as the embodiment of FIG. 1. It can be seen that the concept is broadly to provide a contacting layer 16, an intermediate layer 18 and an inner core body 12.
In the event electrically heating or the like is not desired, fiber optic wire may be used in place of core wire 12. It will heat upon being exposed at its proximal end 12a to laser energy. Again, the broad concept is to provide means for providing an appropriate stimulus to layer 18 so as to change its condition from a solid condition to a "release" condition such as a softened condition.
Quartz fiber or high quartz glass of 500 microns in diameter or thereabout may be used as optical fiber and to form supporting reinforcement. However, the softening point is well above the "safe" temperature range of interest. If such fibers were formed into a coil, they would be difficult to withdraw. If the coil so formed were of smaller diameter than the expanded diameter and, therefore dependent on layer 18 and/or 16 to hold the device in the expanded position, then the function of support (reinforcement) would reside in element 14 (layer 16 and/or 18). Multiple thin fibers may be constructed to be sufficiently flexible to be removed but not also for support. Therefore, in most cases if radiation is to be used as the source of energy, very thin flexible fibers must be combined with other structural components.
Referring now to FIG. 5, a double core wire version of the invention is shown. In other respects it is similar to that of FIG. 1 in that core wires 12 are coated with the two-layer "bio" material as before. However, in this embodiment, the core wires 12 are used in a helix-like double loop configuration as shown in FIG. 5. Optionally, if an electrical resistance heating approach is to be used for heating the inner layer 18, the core 12 may include a section which is linked together at 28 by a fusible material which melts as shown in FIG. 6 at the heating temperature generated in the cores by the source of energy such as shown in FIG. 1. Of course the cores need not be fused together or even joined at their distal ends in any way. In such event, another arrangement and means for heating may be utilized. Also, the variation of FIG. 4 may be used in the embodiment of FIG. 5.
FIG. 7 is included to illustrate that more than two cores may be used. In this Figure three coated cores 14 are illustrated in this version.
Turning now to the embodiment shown in FIG. 8 and FIG. 9, a slightly different approach is used. In this version, the "bio" material may be a single layer 16 of material which is selected to have mechanical support properties so as to form a tube. Layer 18 is not required in this version but may be optionally included as shown. A single reinforcing coil 12 is carried within the tubular configuration of the stent and may be removed by simply pulling it out when desired. Typically, temporary stents are in place for 12-68 hours or so. It may be that tubular material 16 be formed with openings (not shown) therein for circulation. These may be formed by mechanical or chemical means such as drilling, laser penetration, etching, dissolution or soluble component, etc.
FIG. 10 shows a version similar to that of FIGS. 8 and 9 and similar to FIG. 5 in that two cores 12 are used in the tube 16. As in FIG. 5, cores 12 may be fused at 28 if desired and layer 18 may be optionally included.
Referring to FIGS. 11 and 12, yet another approach is shown that is similar to FIGS. 1-2 in that core wire 12 is sheathed in bio material element 14. However, an elongate balloon 40 such as that used in angioplasty PTCA applications is also included. Balloon 40 is arranged to enclose core 12 over its length inside the stent proper as shown. During implant it is inflated. When removal is desired, it is deflated and removed along with core 12 by pulling it out through the guiding catheter.
FIGS. 13 and 14 demonstrate another embodiment of the invention which is similar to FIG. 10, except that in this case the core wire 12 and "bio" layer 18 are engulfed in a cylindrical tube or sleeve composed of biomaterial 16. FIG. 14 illustrates a cross-sectional view of FIG. 13 showing the core wire 12 and its layer covering 18 embedded in biomaterial 16.
Catheter connection to the balloon for inflation/deflation are as typically used in PTCA and need not be described in detail.
The biodegradable material may also be used as an outer layer on a Nitinol™ stent which could be removed after its purpose is accomplished leaving the biomaterial against the vessel wall or the kind, hence preventing disruption of the vessel walls healing process.
The stent may also be covered by a protective sleeve (not shown) which would be removed after crossing the lesion and correct positioning is achieved just before the balloon inflation.
While this invention may be embodied in many different forms, there are described in detail herein specific preferred embodiments of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated.
The above Examples and disclosure are intended to be illustrative and not exhaustive. These examples and description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the attached claims. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims attached hereto. | This invention concerns an improved removable stent for temporary placement within a body. A stent according to the present invention utilizes a removable coil or the like of reinforcing filament such as metal or plastic wire enclosed at least partially within a shell or within a covering of biodegradable/bioabsorbable material which is allowed to remain within the body after removal of the reinforcing filament. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to bandgap voltage reference circuits, and more particularly to such circuits in which an attempt is made to correct for a Tln(T) deviation from linearity in the output voltage.
2. Description of the Prior Art
Bandgap reference circuits have been developed to provide a stable voltage supply that is insensitive to temperature variations over a wide temperature range. These circuits operate on the principle of compensating the negative temperature drift of a bipolar transistor's base-emitter voltage (V be ) with the positive temperature coefficient of the thermal voltage V T , which is equal to kT/q, where k is Boltzmann's constant, T is the absolute temperature in degrees Kelvin and q is the electronic charge. A known negative temperature drift due to V be is first generated. A positive temperature drift due to the thermal voltage is then produced, and is scaled and subtracted from the negative temperature drift to obtain a nominally zero temperature dependence. Numerous variations in the bandgap reference circuitry have been designed, and are discussed for example in Grebene, Bipolar and MOS Analog Integrated Circuit Design, John Wiley & Sons, 1984, pages 206-209.
Although the output of a bandgap voltage cell is ideally independent of temperature, or at least varies linearally with temperature, the outputs of prior cells have been found to include a term that varies with Tln(T), where 1n is the natural logarithm function. Such an output deviation is shown in FIG. 1, in which the bandgap voltage output (V bg ) increases from a value of about 1.2408 volts at -50° C. to about 1.2444 volts at about 45° C., and then returns back to about 1.2408 volts at 150° C. This output deviation is not symmetrical; its peak is skewed about 5° C. below the midpoint of the temperature range.
It is difficult to precisely compensate for the Tln(T) deviation electronically, so simpler approximations have been used. One such circuit is shown in FIG. 2, and is described in U.S. Pat. No. 4,808,908 to Lewis et al., assigned to Analog Devices, Inc., the assignee of the present invention. The circuit includes bipolar npn transistors Q1 and Q2, with the emitter area of Q2 scaled larger than that of Q1 by a factor A. The emitters of Q1 and Q2 are connected together through a resistor R1 that has a relatively low temperature coefficient of resistance (TCR). A second relatively low TCR resistor R2 is connected in series with a relatively high TCR resistor R3 between the R1/Q1 emitter junction and a negative (or ground) voltage bus V-. Q1 and Q2 are provided with collector currents with a constant ratio between the current magnitudes, such as by connecting their collectors respectively to the inverting and non-inverting inputs of an operational amplifier. R1 and R2 are preferably implemented as thin film resistors, with TCRs on the order of 30 ppm (parts per million)/°C.; such low TCRs may be considered to be negligibly small for purposes of the invention. R3 is preferably a diffused resistor having a TCR of typically 1,500-2,000 ppm/°C.
The output voltage V bg is equal to the sum of V be for Q1 and the voltage drops across R2 and R3. In the absence of R3, the voltage across R2 can be determined by considering the voltage across R1. This is equal to the difference in V be for Q1 and Q2; since the emitter of Q2 is larger than the emitter of Q1 but both transistors may carry equal currents, the emitter current density of Q2 will be less than for Q1 and Q2 will accordingly exhibit a smaller V be . The V be differential between Q1 and Q2 will have the form V T ln (Id1/Id2)=V T ln(A), where I1 and I2 are the absolute emitter currents, and Id1 and Id2 are the emitter current densities of Q1 and Q2, respectively. Since I1 is preferably equal to I2, the current through R2 will be twice the current through R1, so that the voltage across R2 will have the form (2R1/R2)V T ln(A). Still ignoring R3, the described circuit will exhibit the Tln(T) output deviation mentioned above.
The addition of high TCR resistor R3 approximates a Tln(T) output voltage compensation by producing a square law (T 2 ) term that is added to V bg . Since the tail current through R2 is proportional to temperature anyway, adding a significant temperature coefficient by means of the high TCR tail resistor R3 yields a voltage across this resistance that is proportional to T 2 . Combining this square law voltage with the voltage across R2 and V be for Q1 approximately cancels the effect of the Tln(T) deviation.
R3 is preferably a diffused resistor, which is not subject to trimming. However, the resistance values of thin film resistors R1 and R2 can be conveniently adjusted by laser trimming to minimize the first and second derivatives of the bandgap cell output as a function of temperature.
Unfortunately, the square law voltage compensation produced by the FIG. 2 circuit is perfectly symmetrical, as opposed to the skewed parabolic shape of the Tln(T) deviation that actually characterizes the bandgap cell. Thus, the voltage correction that can be achieved with the FIG. 2 circuit is limited. FIG. 3 compares the Tln(T) and T 2 functions, scaled to a normalized value of the correction voltage V corr . The resulting variation in the net V bg , plotted on a normalized scale in which zero is the nominal V bg , is illustrated in FIG. 4. This is a sideways S-shaped curve that exhibits a significant residual temperature coefficient in both the upper and lower portions of the temperature range.
SUMMARY OF THE INVENTION
The present invention seeks to provide a precise compensation for the Tln(T) deviation of a bandgap reference cell, without unduly complicating the circuitry or adding process steps, and with a compensation mechanism that is adjustable to account for manufacturing tolerances.
These goals are achieved by adding a relatively low TCR resistor in parallel with the high TCR tail resistor of a bandgap voltage reference as described in FIG. 2. This produces a resistance circuit that is non-linear with respect to temperature, such that when a proportional-to-absolute-temperature (PTAT) current is passed through it the voltage across the resistor circuit is very similar to the Tln(T) function. The ratio of resistance values between the two parallel resistors is selected so that, as a function of temperature, the rate of change in the cell's output voltage both with and without the parallel resistors is substantially zero at approximately the same temperature. This establishes a shape for the compensation voltage-temperature characteristic that closely matches the Tln(T) deviation. The absolute resistance values of the parallel resistors are selected so that the compensation scale matches to the deviation scale. The correction resistor is preferably implemented as a laser trimmable thin film resistor, formed from the same type of material as the other low TCR resistors in the circuit. The result is a highly accurate output correction that can be implemented with a minimum of additional elements and processing.
These and other features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of a typical Tln(T) deviation, described above, for a known bandgap voltage reference circuit;
FIG. 2 is a schematic diagram of a known bandgap voltage reference circuit, described above, that partially compensates for the output deviation shown in FIG. 1;
FIG. 3 is a graph, described above, comparing the Tln(T) deviation of a standard bandgap voltage reference circuit with the compensation provided by the circuit of FIG. 2.
FIG. 4 is a graph, described above, illustrating the voltage output obtained with the circuit of FIG. 2;
FIG. 5 is a schematic diagram of a bandgap voltage reference circuit that incorporates the present invention;
FIG. 6 is a graph illustrating the non-linearity, as a function of temperature, of the parallel resistor combination of FIG. 5;
FIG. 7 is a graph illustrating a family of correction voltage-temperature curves achievable with the invention for different ratios between the low TCR correction resistor and the high TCR tail resistor;
FIG. 8 is a graph plotting the slopes of the various curves in FIG. 7 at a temperature corresponding to the peak Tln(T) deviation temperature;
FIG. 9 is a graph illustrating the voltage output achievable with the invention;
FIG. 10 is a graph comparing the bandgap voltage outputs with and without the correction provided by the invention; and
FIG. 11 is a family of curves similar to FIG. 8, showing the effects upon the ideal resistor ratio of varying the TCR of the high TCR tail resistor.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A bandgap voltage reference circuit that compensates for the Tln(T) deviation to achieve an essentially temperature-invariant output is shown in FIG. 5. Circuit elements that correspond to those of the prior bandgap reference cell shown in FIG. 2 are indicated by the same reference numerals.
Various known schemes are possible to establish a constant ratio of currents through Q1 and Q2 that does not vary significantly with temperature. One such technique, illustrated in the figure, is to connect low TCR load resistors RL1 and RL2 between the collectors of bandgap transistors Q1 and Q2, respectively, and a positive voltage bus V+. The voltages at the opposite sides of RL1 and RL2 from V+ are maintained at the same constant voltage levels by connecting these points respectively to the non-inverting and inverting inputs of an operational amplifier 2, the output of which is connected to the cell's output terminal 4. The operational amplifier 2 forces the voltages at its inputs to equal values, thus establishing currents through the load resistors RL1 and RL2 that are inversely proportional to their resistance values; the load resistor currents continue on as the collector currents of Q1 and Q2.
In accordance with the invention, an additional low TCR resistor R4 is connected in parallel with the relatively high TCR resistor R3. By a careful selection of the ratio of resistance values between R4 and R3, a voltage-temperature compensation can be achieved that has essentially the same shape as the Tln(T) output deviation of the circuit without R3 and R4, but with an inverted polarity. The absolute resistor values are then selected to equalize the scalings of the compensation and deviation voltages, so that the output deviation is essentially cancelled by the compensation voltage.
The low TCR resistors R1, R2 and R4 can all be formed in the same process step, and are preferably thin film resistors. Such resistors have a TCR on the order of 30 ppm, which is negligible for purposes of the invention. The high TCR resistor R3 can be implemented in various ways, such as by a diffused resistor with a TCR of about 1500 ppm/°C., a polysilicon resistor that also has a TCR of about 1500 ppm/°C., a p-well resistor with a TCR of about 8,000 ppm/°C. or a pinch resistor with a TCR of about 10,000 ppm/°C. An advantage of forming the low TCR correction resistor R4 as a thin film device is that such resistors are easily laser trimmable. As described below, R4 can be trimmed to compensate for fairly large fabrication tolerances without greatly disturbing the output voltage compensation.
FIG. 6 illustrates the non-linearity in the resistance of the R3/R4 parallel circuit as a function of temperature. Normalized resistance values and a unity resistance ratio were assumed for simplification. As described below, the invention takes advantage of this non-linearity to shape and scale a correction factor for the cell's Tln(T) output deviation.
It has been found that, as a function of temperature, the correction voltage (V corr ) across the R3/R4 parallel combination varies considerably with the ratio of the resistance value of R4 to R3. Computed traces of the correction voltage as a function of temperature for different resistance ratios are given in FIG. 7, with the resistance ratio increasing in increments of 0.5 from zero to eight. With a zero (short circuit) resistance for R4, the correction voltage is similarly zero. With a 0.5 ratio the correction voltage is slightly positive, but thereafter becomes increasingly negative as the ratio progressively increases. In addition to obtaining a larger scale, the shape of the correction voltage curve also shifts as the resistance ratio increases; the temperature at which the peak correction voltage occurs becomes progressively higher with an increasing resistance ratio. This phenomenon is utilized by the invention to select the particular resistor ratio for the most accurate output voltage correction.
It should be noted, from an inspection of the family of voltage-temperature curves in FIG. 7, that a first order effect of varying the resistance ratio is to change the absolute scale or size of the curvature correction, while the shift in the temperature at which the peak correction voltage is achieved is only a second order effect. Accordingly, so long as the resistance ratio is set at approximately the correct value to obtain a curvature correction curve with the proper shape, the resistance ratio can later be trimmed (by trimming the correction resistor R4) to maintain the output voltage correction without having a significant effect on the shape of the curvature correction. Such trimming may be called for if the desired resistance values for R3 and R4 are not obtained due to manufacturing tolerances. The high TCR resistor R3 will generally be implemented as a diffuse resistor, which is not subject to trimming. On the other hand, the use of thin film for the low TCR correction resistor R4 makes that device easily laser trimmable, as indicated by the trimming laser beam 6 indicated in FIG. 5. This is a valuable feature, since it allows the curvature correction to be trimmed by varying the value of R4 slightly, rather than having to trim the entire bandgap cell current.
A precise output curvature correction is obtained by selecting the particular voltage correction curve that reaches a peak correction voltage at the same temperature at which the peak Tln(T) deviation occurs. For the deviation curve of FIG. 1, the peak deviation occurs at approximately 44.7° C. (FIG. 1 corresponds to a bandgap cell with R1 equal to 21.4 kohms, R2 equal to 121 kohms, transistor collector currents of 3 microamps, a transistor emitter area ratio of 10:1 and a transistor V be of 0.51773 volts.) The slopes of each of the curvature correction curves in FIG. 7 at 44.7° C. are plotted as a continuous curve in FIG. 8. It can be seen that zero slope values, which correspond to a peak correction voltage at 44.7° C., occur at R4/R3 ratios of 0, 0.7 and 5.0. A zero ratio can be ignored, since it corresponds to a short circuit, while a 0.7 ratio is undesirable because it is in the positive compensation portion of FIG. 7 and the compensation scale is very low. A resistor ration of about 5:1 is thus the preferred ratio for achieving an accurate output correction.
Now that the proper resistor ratio for the desired curvature correction curve shape has been determined, the absolute resistance values are computed by computing the curvature correction peak size as the differential between the values of the output deviation voltage at the ends of the temperature range and at the peak deviation temperature. The overall PTAT voltage produced by the high TCR resistor R3 is also computed, and the value of R2 is reduced to compensate for this PTAT voltage. The resulting output deviation, for the resistance parameters described above, is shown in FIG. 9. The voltage scale of this figure is greatly magnified, with each vertical division corresponding to only a single microvolt; the peak-to-peak output voltage deviation has been substantially reduced down to about 5 microvolts.
The output characteristic in FIG. 9 has a pair of humps 8 and 10 that represent a third order correction, as compared the S-shaped output of a second order (square law) curvature correction illustrated in FIG. 4 for the circuit without the correction resistor R4. Also note that the absolute value of the output deviation in FIG. 9 is on the order of 10 4 times less than the deviation in FIG. 4.
FIG. 9 represents an optimized output that is theoretically obtainable if there are no other sources of output deviation. However, a hysterisis in the transistor operation as the temperature increases to the upper end of the desired range and then cools back down to room temperature typically introduces a greater output randomness, on the order of perhaps 100 microvolts, than the degree of accuracy indicated by FIG. 9. The presence of transistor hysterisis mitigates the effect upon absolute output temperature linearity that would otherwise result from trimming the correction resistor R4 and thus changing the R4/R3 resistor ratio. Any loss in output accuracy from trimming R4 would tend to be masked by the hysterisis effect, but the hysterisis deviation is still several orders of magnitude less than the residual deviation that can be expected with a square law output correction.
A comparison of the bandgap cell's output, with and without the curvature correction provided by the invention, is illustrated in FIG. 10 for a circuit with parameters as described above. Curve 12 represents the uncorrected output, while curve 14 represents the output after the addition of the curvature correction. Due to the voltage scale employed, the corrected output appears to be perfectly flat as a function of temperature, while the uncorrected output has a distinct bow.
The particular R4/R3 resistance ratio at which accurate curvature correction is obtained will depend upon the parameters of the particular circuit being considered. For example, the curve of FIG. 8 was obtained with an assumed TCR for R3 of 6,880 ppm/°C. FIG. 11 presents modified curves of the correction voltage-temperature slope, as a function of the resistor ratio, for different values of R3 TCR. Curves 16, 18, 20, 22 and 24 correspond respectively to TCRs of 4,000, 5,000, 6,000, 7,000 and 8,000 ppm/°C. for R3. It can be seen from these curves that the optimum resistor ratio increases progressively from a value of about 3.2 for curve 16 to a value of about 5.7 for curve 24.
While particular embodiments of the invention have been shown and described, numerous variations and alternate embodiments that employ a relatively low TCR correction resistor in parallel with a relatively high TCR tail resistor will occur to those skilled in the art. Accordingly, it is intended that the invention be limited only in terms of the appended claims. | A bandgap voltage reference circuit includes a low temperature coefficient of resistance (TCR) tail resistor connected in series with a high TCR tail resistor, and a low TCR correction resistor connected in parallel with the high TCR resistor. The ratio of resistance values for the parallel resistors is selected to produce a correction voltage that essentially cancels a Tln(T) output deviation from temperature linearity, where T is absolute temperature. Matching voltage-temperature characteristics are obtained by selecting a resistor ratio at which the rate of change in the circuit's output voltage, both with and without the parallel resistors, is substantially zero at approximately the same temperature. While the shape of the compensation voltage-temperature curve is determined by the resistor ratio, it is scaled to the magnitude of the Tln(T) deviation by an appropriate selection of absolute resistor values. The correction resistor is preferably a trimmable thin film element. | 8 |
This application is a continuation of application Ser. No. 07/075,185, filed July 13, 1987 abandoned, which is a continuation of Ser. No. 06/811,778 filed Dec. 20, 1985 abandoned.
BACKGROUND OF THE INVENTION
Down-the-hole drills are generally known in the art. One such drill has been shown and described in U.S. Pat. No. 4,084,646 issued to Ewald H. Kurt and assigned to Ingersoll-Rand Company. The drawings and specifications of that patent are hereby incorporated by reference to describe the basic drill and similar drills to which the present invention applies.
OBJECT OF THE INVENTION
An object of the invention is to increase the effective volume in front of the impact piston without increasing the diameter of the drill.
A further object of this invention is to reduce the effective back pressure developed on the impact piston of a down-the-hole drill in order to improve its deep hole work output.
Yet a further object of this invention is to provide an impact piston with a reduced diameter section forming an accumulator of pressure fluid which travels with the piston without biasing the piston in directions of travel.
Another object of the present invention is to provide a down-the-hole drill with increased work output at higher back pressures experienced in deep holes without increasing the diameter of the drill.
These and other objects are obtained in a percussive drill apparatus of the valveless type comprising:
a casing; a backhead disposed at the back end of the casing adapted to connect the drill apparatus to a drill string and a source of pressure fluid; a distributor disposed within the casing towards the back end of the casing; a percussive member disposed at the front end of the casing to form a chamber having a back end disposed towards the distributor and a front end disposed towards the percussive member between the distributor and the percussive member within the casing; a cylinder sleeve disposed in the chamber toward the back end of the chamber; a first pressure fluid passage formed between the casing and the cylinder sleeve to connect the pressure fluid source to the chamber; a piston disposed in the chamber to reciprocate axially therein and impart a blow on the percussive member; the piston being in sliding contact with the cylinder sleeve adjacent the back end of the chamber and in sliding contact with the casing adjacent the front end of the chamber; a means for continuously applying pressure fluid to a selected portion of the back end of the piston to thereby provide a continued driving force on the piston towards the front end of the chamber; a means for alternately supplying and exhausting pressure fluid to a selected portion of one side of the piston disposed towards the back end of the chamber and to a selected portion of the other side of the piston disposed towards the front end of the chamber to thereby reciprocate the piston; the means for alternately supplying and exhausting pressure fluid to the back side of the piston includes a second pressure fluid passage extending from the first pressure fluid passage along the interior of the sleeve and the exterior of the piston;
The improvement comprising:
A means for accumulating additional pressure fluid in a portion of the piston dispersed towards the front end; and a means for communicating the means for accumulating additional pressure fluid with the first pressure fluid passage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal section of the center portion of a pneumatic down-the-hole rock drill according to the prior art.
FIG. 2 is a longitudinal section of the center portion of a pneumatic down-the-hole rock drill according to the present invention.
FIG. 3 is a cross sectional view of the prior art rock drill taken at section 3--3 shown on FIG. 1.
FIG. 4 is a cross sectional view of the rock drill according to the prior art taken at section 4--4.
FIG. 5 is a cross sectional view of the rock drill according to the present invention taken at section 5--5.
FIG. 6 is a cross sectional view of the rock drill according to the present invention taken at section 6--6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The drawings are numbered to correspond with similar parts in U.S. Pat. No. 4,048,646 for easy identification and comparison. However, for purposes of understanding this invention it is necessary to know that, in a conventional down hole drill and similar reciprocating hammer devices driven by a pressurized gas, when the pressure fluid enters the area in front of the piston on its down stroke it restrains the piston. If this occurs prior to piston impact as it does in the referenced patent, it reduces the maximum obtainable impact.
In the referenced valveless design some overlap or early introduction of pressure fluid in the frontal area is required for the cycles to operate effectively and the present invention is directed at reducing the restraining effect prior to impact. I have determined that one way this may be accomplished is to effectively increase the volume associated with the frontal area of the impact piston. Since this volume must be pressurized a greater flow of pressure fluid is required to effect the same back pressure. Since the flow of pressure fluid is to some degree restricted by limitation of design in down-the-hole drills this results in an effective time delay in reaching full pressure below the piston. The delay results in increased piston impact while retaining the overlap required for the cycle to operate. The above is particularly effective where as in a deep hole, the exhaust back pressure is substantial and the frontal area pressure is therefore already relatively high.
Referring to FIG. 1 a rock drill longitudinal section is shown to illustrate the concerned parts of a down-the-hole pneumatic drill according to U.S. Pat. No. 4,048,646.
Briefly, in this pneumatic drill the air passes through the drilled ports 63 in the cylinder sleeve 50 into an annular passageway 52 between the outside diameter of the cylinder sleeve 50 and the inside of the casing 6.
From here the air moves forward into chamber 64 between the piston outside surface and the casing 6 inside diameter. This is an "air reservoir space" because there is always pressure fluid in this chamber and it is from here that the air passes either to the upper chamber 68 of the piston or the lower chamber 69 of the piston. With the piston in its lower position (shown in FIG. 1 which it would attain before the air is turned on, the air passes into the lower chamber 69, exerting a force on the lower impact imparting surface 40 of the piston 30, driving it upwards towards its one or inlet end. The air continues to feed into the lower chamber 69 or V1 and is trapped between the piston 30, the bit 8, the casing 6 and a spacer ring 13 until the lower sealing surface 37 of the casing, that is, until edge 86 contacts shoulder 87. When this occurs, air is shut off to the lower chamber 69. The piston continues to move upwards, however, by virtue of its velocity and expansion of the air in the lower chamber. As the piston rises, the lower sealing surface of the axial bore 42 of piston 30 pulls off the end of the exhaust tube 23. At this point, the air in the lower chamber 69 exhausts it to the drill bit 8 and out into the exhaust bore 67.
While this is going on at the lower end of the piston, other events are occurring at the upper end. The first is that the upper chamber 68 is sealed off as the sealing surface 43 of the piston axial bore engages the lower end of the enlarged head 66 of the exhaust rod 65 of the distributor. Shortly thereafter, pressure fluid is admitted, via axial porting slots 33, into the upper chamber 68 as edge 88 of the piston slots 36 uncover the shoulder 89 of the undercut 80 inside the cylinder sleeve 50. The air entering the upper chamber 68 first stops the piston on its upwards travel (about an inch from hitting the distributor) and then reverses the piston travel, pushing it forward at increasing velocity. The pressure fluid flow to the upper chamber 68 is shut off as edge 88 of the piston slots 36 cover the shoulder 89 of the undercut 80. From this point on, the piston is driven by expanding pressure fluid. When sealing surface 43 loses contact with enlarged head 66 of the distributor exhaust rod, air in the upper chamber 68 is exhausted through the piston 30, into the exhaust tube 23 and out the bit 8 as the piston continues to move towards its impact on other end, edge 86 of the lower sealing surface 39 of the piston 30 loses contact with the shoulder 87 of internal surface 39 of the casing again at which point air re-enters the lower chamber 69. Shortly thereafter, the piston 30 impacts against the bit 8. The piston rebounds somewhat. This, plus the air re-entering the lower chamber, starts the next cycle.
As can be appreciated by one skilled in the art once the edge of the lower sealing surface 39 loses contact with the shoulder 87 and air begins to enter the lower chamber, the piston 30 begins to loose velocity as a result of the force of such air action on the lower impact surface 40 of the piston. This results in energy loss and it is therefor desirable to minimize the pressure developed in chamber 69.
The pressure build up in chamber 69 has been substantially reduced by the present invention. As shown in FIG. 2 the piston 30 is provided with a substantial circumferential undercut 100 which forms a substantial volume V2 for the accumulation of pressure fluid. Shoulder 34 of the prior art device has been extended outward to form an upper circumferential sealing surface 101 of the same diameter as lower circumferential sealing surface 39.
The casing internal fluted longitudinal passages 102 have been extended to perform the same function, at shoulder 87' in cooperation with edge 86' of upper sealing surface 101, as edge 86 performed with shoulder 87 in the prior art and at the approximate same point in cycle timing.
FIGS. 3 and 6 compare the cross sections taken at sections 3--3 and 6--6 respectively in FIGS. 1 and 2.
FIGS. 4 and 5 compare the cross sections through the piston at sections 4--4 and 5--5 respectively in FIGS. 1 and 2. These clearly show the reduced piston diameter in FIG. 5 which forms volume V2.
It can now be appreciated by one skilled in the art that, once the upper sealing surface 101 loses contact with shoulder 87', in order for pressure to build up the pressure fluid or air must fill both volume V1 and V2. With a given available flow of air the total pressure build up is time delayed thereby substantially reducing the retarding force on the piston and dramatically increasing the impact of the piston on the bit.
The results have been most impressive particularly in deep holes where the back pressure or exhaust already reduces piston impact and where the slightly increased air flow resulting for the increased front end volume is of benefit air cleaning the hole.
Having described my invention numerous modifications will now occur to one skilled in the art and I do not wish to be limited in the scope of my invention except as claimed. | A fluid impact tool is disclosed of the type commonly known as a down-the-hole drill for drilling of rock. The improvement herein described increases deep hole drill performance by providing a means for accumulating piston return air in a traveling air pocket found on the piston. This effectively increases the piston front end volume so as to decrease the effect of the front end air cushion and thereby increase impact. This is particularly effective during operation with increased back pressure such as found in deep holes. | 4 |
RELATED APPLICATION
This application is a continuation of our earlier filed U.S. patent application Ser. No. 629,677 filed July 11, 1984, now abandoned, the disclosure and contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention lies in the field of production techniques for silicon bodies, particularly polycrystalline large-area silicon bodies such as are useful for further processing into solar cells.
2. Prior Art
The cheapest silicon possible should be employed for the manufacture of solar cells from silicon since the demands made of these components with respect to crystal quality are not as high as in the case of semiconductor elements employable for integrated circuits. A way was therefore to be found for manufacaturing silicon crystals in a simple and inexpensive manner, i.e. without material losses insofar as possible.
A method of the type just cited is disclosed in the DE-OS No. 28 50 805. Planar silicon with a high throughput (1 m/min) can be produced for solar cells with this method in that a carrier member comprised of graphite which is provided with holes is tangentially drawn across the surface of a silicon melt in a through-feed process, whereby the carrier member is integrated in the produced silicon bodies upon crystallization of the silicon. A disadvantage of this method is that convectional currents can occur in the melt.
A further improvement with respect to the crystal quality is achieved when, as proposed in the [German] patent application No. 32 31 326.8, the molten silicon is supplied to the carrier member by means of capillaries. The capillaries discharge into a horizontal gap through which a carrier member is drawn for coating. Such carrier member consists of graphite threads and has a net-like structure. Given this drawing apparatus, the melt level in the silicon reservoir lies 10 to 15 mm lower than the horizontal gap for technical reasons. The consequence thereof is that a hydrostatic pressure ρ·g·h acts on the silicon melt which is picked up and entrained by the meshes of the carrier member, whereby h=10 through 15 mm, ρ=the density of silicon, g=gravity, thus limiting the maximally fillable mesh size dimenstions to about 5 mm×5 mm.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to a method for the manufacture of polycrystalline, large-area silicon bodies, such as are particularly employed for further processing into solar cells, by means of coating a carrier member which is resistent to molten silicon, but which is wettable by a silicon melt. The carrier member comprises a net-like structure. The invention also relates to an apparatus for the implementation of such method.
A principal object of this invention is to manufacture a planar silicon body in a tape or ribbon form with a crystal quality at least sufficing for solar cells. In such manufacture, a graphite net or a graphitized silica glass (quartz) net having mesh dimensions up to of about 10 mm×10 mm (100mm 2 ) can be unproblematically employed as carrier member for such a coating. A further object of the invention is to produce silicon crystal bodies which are as large-area and as uniform as possible with respect to the coating using the most cost-favorable initial material. A further object is to provide an apparatus for use in such manufacture which is simply constructed and permits a high throughput.
In order to achieve the inventive objects, a method of the type initially cited is provided which is characterized in that the carrier net member existing in tape or ribbon form is brought into contact with a succession of silicon bodies each consisting of silicon crystal grains of small size. Such an individual silicon body exists in a sheet or a plate form and generally coincides with the carrier member with respect to its dimensions. An assembly of carrier members and silicon bodies is exposed horizontally to a heater arrangement so that each silicon body is generally planarly disposed upon the carrier member and is caused to melt. The silicon melt is deposited in the meshes of the carrier net and is induced to crystallize.
It lies within the scope of the invention that a suitable starting silicon plate (or sheet) can be produced by means of sintering silicon powder. Also, a starting silicon plate (or sheet) can be manufactured by means of spraying molten silicon onto a cooled drum can. The mesh dimensions of the carrier member consisting of a graphite thread net, or a graphitized silica glass thread net, can range up to about 10 mm×10 mm (100 mm 2 ).
Provided for the implementation of the inventive method is an apparatus which is characterized by the following features:
(a) a horizontally disposed heater arrangement consisting of a plurality of separately regulatable heating zones,
(b) a conveyor apparatus including conveyor drive means which moves a carrier ribbon horizontally through the heater arrangement,
(c) a carrier ribbon supply drum means disposed in front of the heater arrangement from which a tape-configured carrier member is unwound,
(d) a storage drum means disposed after the heater arrangement on which the product coated carrier member is taken up, and
(e) a silicon plate feeder means disposed in front of the heater arrangement and above the supply drum including silicon plates storage means, and including a feeder drive means, said feeder means being adapted to supply silicon plates upon the carrier member in a time-controlled sequence.
Other and further objects, aims, purposes, features and advantages, aspects, embodiments, and the like will be apparent from the teachings of the present specification taken with the attached drawings and claims.
BRIEF DESCRIPTION OF DRAWINGS
In the drawings:
FIG. 1 is a schematic side elevational view of a heater arrangement used in the apparatus for this invention;
FIG. 2 is a schematic detailed view of the melting and crystallizing regions of the heater arrangement of FIG. 1;
FIG. 3 is a view similar to FIG. 2, but illustrating an alternative arrangement; and
FIG. 4 is a schematic side elevational view of a feeder means suitable for apparatus of this invention.
DETAILED DESCRIPTION
The process of this invention can be practiced batchwise or continuously.
A continuous rush of practice is herein preferred and is no described. Referring to FIG. 1, a plurality of individual planar silicon bodies 1 are initially situated in a magazine or tray stack of a feeder means 13 (shown in FIG. 4). Each body or plate 1 consists of sintered or sprayed silicon and each plate is successively laid down in registration with a continuously moving carrier belt member 2 consisting of a net formed of graphite thread or of a net formed of graphitized silica glass thread. The assembly of belt 2 and bodies 1 thereon moves horizontally through a heater arrangement in which the silicon is caused to melt in a zone or region 10, and to disperse into the meshes of the net of carrier member 2. The resulting composite or coated carrier is conveyed past an output gap 3. The heater arrangement itself comprises a plurality of separately regulatable furnaces or heaters, such as 4, 5, 6, and 7. A pre-heating each silicon plate 1 is accomplished by furnace 4 before the melting region 10, a post-meet heating is accomplished by furnace 7 after the composite passes out of the melting region 10. Melting region 10 is here provided by melting furnaces 5 and 6 located in opposed relationship to one another above plates 1 and below carrier 2, respectively.
A crystallization of the molten silicon in the meshes of the carrier member 2 is promoted by a cooling means 8. An integrated composite crystallized silicon and graphite net structure 12 results. The arrows 9 indicate the conveying direction. Given, for example, individual mesh width and length dimensions of about 10 mm by 10 mm, a conveying speed is conveniently set at a value of about 50 cm/min, for example.
The single-sided pre-heating by furnace 4 of each silicon sheet 1 is conveniently accomplished by an average temperature of about 1200° C., for example, and is intended to prevent the graphite thread net of carrier 2 from remaining at a high temperature for an unnecessarily long time which possibly could result in the undesired emission of contaminants.
A controlled solidification of the silicon melt in meshes of carrier 2 is promoted by means of an after-heating by furnace 7 from below carrier 2 at a mean temperature of from about 1000° to 1400° C. Simultaneously from above a cooling of the composite is provided by cooling means 8. The thickness of the silicon melt achieved in the carrier member 2 is thereby inversely proportional to the mesh width of the carrier member 2, that is, the crystallized silicon tape 12 becomes thinner as the individual mesh perimeter dimensions increase. Given individual mesh width and length dimensions of about 5 mm by 5 mm, for example, the thickness of an integrated composite crystallized silicon/graphite net structure 12 lies below about 1 mm.
Referring to FIG. 2, detail of the transition from the silicon melt region 10 into the integrated crystallized silicon graphite net structure 12 is seen. The same reference characters apply as in FIG. 1, but the after-heating zone provided by furnace 7 as well as the pre-heating zone provided by furnace 4 are not shown in the drawing. The crystallization front or zone is referenced by the numeral 11.
Referring to FIG. 3, there is seen a modification of the apparatus as shown in FIG. 2 which modification is particularly suitable for the manufacture of flat silicon tapes. Here, the furnaces or heaters 5 and 6 simultaneously serve for melting the individual silicon sheets 1 and for shaping the resulting integrated structure 12. The pre-heating furnace 4 as well as the gap 3 have not been shown here for the sake of greater clarity.
Given manufacture of planar silicon integrated with net-like carrier member in a tape or sheet form according to the teachings of the invention, a carrier 2 can have mesh width and length dimensions of up to about 10 mm by 10 mm each (100 mm 2 ). Larger mesh sizes within this range have the following advantages:
1. A large net width means low substrate costs.
2. The horizontal supplying of the silicon plates upon the carrier net results in the hydro-static pressure ρ·g·h playing no role in the filling of the individual meshes because h≃0.
3. Due to the substrate material employed, the silicon body which is crystallized in the meshes contains only a low contaminant level.
4. The arrangement of the heating zones in the apparatus can be made so as to supply a high crystal quality in the product integrated structure.
The advantages revealed under points 3 and 4 (above) have a very beneficial effect on the efficiency of the solar cells produced from these product integrated structures (approximately 12%).
Referring to FIG. 4, details of a feeder arrangement for successively depositing individual silicon plates 1 upon carrier member 2 are shown. For the sake of greater clarity, the individual heaters of the heater arrangement are omitted. The same reference characters as in FIGS. 1 through 3 apply and the arrow 19 indicates the conveyor apparatus (not detailed) used for moving carrier (2).
The silicon plates 1 are expediently manufactured by sintering according to the method disclosed in the DE-OS No. 29 27 086. The initial material is silicon power having individual granule sizes of less than about 1 mm. This silicon powder is stirred into a slip with a bonding agent and the slip is drawn out to a film on a foundation with a drawing shoe. The film is dried and the foundation is removed. The film is then cut to a size which corresponds to the dimensions of an individual solar cell (for example, 10 cm×10 cm), taking the shrinkage during sintering into consideration. The pre-sintering of the film which leads to production of self-supporting plates 1 ensues at temperatures between about 1250° C. and 1300° C. Since a self-supporting, compressed sheet or film can already by employed, the temperature management is thereby of subordinate significance.
As can be seen from FIG. 4, the individual sintered silicon plates 1 are stacked one above the other in a tray-like manner in the feeder means 13. As the carrier member 2 continuously travels in the direction shown by arrow 20 beneath the feeder means 13 by means of a conveyor means 19 (not detailed in the drawing), the individual silicon sheets 1 are deposited thereon sequentially at desired intervals, as shown, for example, in FIG. 4. Alternatively, the sheets 1 can extend continuously on carrier member 2. The carrier member 2 consisting of a belt or tape or ribbon-configured graphite net which is unwound horizontally from a supply drum or reel 14 before silicon plates 1 are laid thereon, and the resulting heat treated and crystallized composite structure can be rewound onto a storage drum (not shown) after it has been prepared according to the invention. The feeder means 13 itself consists of two pairs of rollers 15 and 16 disposed in spaced, parallel relationship relative to one another, whereby two respective rollers 15a and 16a, and 15b and 16b, each disposed one above another respectively, are provided with an endlessly circulating conveyor belt 15c and 16c (similar to a two-sided conveyor belt). Naps or teeth 17 are situated upstandingly at longitudinally spaced intervals on the surface of each endless belt 15c and 16c and serve as a seating surface or platform for supporting the individual silicon sheets 1. The roller pairs 15a, 16a, and 15b, 16b, are placed in synchronized motion by means of a drive (not detailed) indicated by the arrows 18 in the FIG. 4 so that a carrier member 2 consisting of a graphite net has deposited thereon the individual silicon sheets 1 at specific intervals under time control and the so equipped carrier member 2 is continuously supplied to the heater arrangement in the direction of arrow 19. After the crystallization of the molten silicon in the meshes of the carrier 2 individual solar cells are then obtainable by means of simple severing of the product composite tape.
Although various minor modifications may be suggested by those versed in the art, it should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art. | A method and an apparatus is provided for the manufacture of large-area silicon crystal bodies useful for solar cells. A carrier member consisting of a net-like graphite fabric or quartz fabric is moved horizontally through a heater arrangement carrying silicon plates on its surface which are matched to the dimensions of the carrier member. The silicon body is caused to melt and the molten silicon fills in the meshes of the net after which crystallization is induced. Meshes having dimensions up to about 10 mm×10 mm are thus filled with silicon. The technique involves low production costs and high product crystal quality and serves for the continuous manufacture of silicon ribbons for solar cells. | 2 |
CROSS-REFERENCE INFORMATION
The present invention is a continuation-in-part of patent application Ser. No. 10/083,726, entitled “An Online Marketplace For Moving and Relocation Services,” filed on Oct. 19, 2001, and now issued as U.S. Pat. No. 7,487,111 B2, the contents of which is fully incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates generally to a payment and review system for an online marketplace in a computer network environment, and more particularly, to a system for payment retrieval by vendors for rendered services and review of customers who received the services.
BACKGROUND OF THE INVENTION
Typically, a customer pays for service after the service is rendered. For example, a service provider such as a mover, a handyman, a plumber or an electrician will provide service for a customer at the customer's location. At the completion of the service, or job, the customer will pay the service provider, also referred to herein as a vendor. The basic service and payment transaction is straightforward. However, as the transaction is completed as soon as the customer pays the vendor, there should be further incentive for either party to engage in further communications. Typically, unless a customer has received either extremely good or extremely poor service from the vendor, that customer has little motivation to provide feedback about the services the customer received from the vendor.
Although feedback from customers is important for vendors, who use it to improve their services, having customer feedback is especially important in online marketplaces, where customers can select from a variety of vendors. The online marketplace is typically operated by a third party (i.e., an entity other than the vendor or customer), who receives a fee for each transaction between a customer and a vendor. The more transactions that occur in the marketplace, the more fees the third party receives. In order to continue to build goodwill with customers, the operator of the online marketplace would like to provide a system through which any customer that uses the marketplace can help to ensure himself/herself to have a good experience in that the vendor chosen by the customer provides an expected level of service.
One method for matching customer expectation with vendor capabilities is to implement a feedback system on the online marketplace where a customer can evaluate a particular vendor by reviewing feedback from the previous customers of the vendor. For example, in the case of emove.com, which is website operated by eMove, Inc. that provides an online marketplace for moving services, a vendor can be evaluated by the feedback provided by its previous customers. The feedback occurs after the vendor has provided the services.
As the customer who is moving is typically more concerned about the actual move, where a multitude of tasks need to be completed, than filling out reviews, providing a mechanism to facilitate feedback submission is a challenge. Most likely, if the customer has a computer, it is inaccessible as it is being moved itself, dramatically reducing the likelihood of the customer providing feedback for a vendor that has provided services as it requires the customer to seek out Internet access. Moreover, requiring a customer to “login” by remembering usernames or passwords assigned before the move when returning to the online marketplace to respond to a review after the move adds an additional layer of complication that makes the review process inconvenient to complete.
Conversely, vendors are interested in being paid for their services as soon as they have provided them, in addition to receiving feedback from customers. Vendors also want to ensure that any reviews provided for their services are based on actual work they have performed and completed, with an emphasis on receiving feedback as soon as the work is completed.
Accordingly, there is a need for a system that can provide payment to vendors and obtain feedback from customers with a minimal amount of effort by all parties involved.
SUMMARY OF THE PREFERRED EMBODIMENTS
In one preferred embodiment of the present invention, a method is provided that allows a vendor to retrieve payment for services rendered while simultaneously transmitting an e-mail message to the customer with a link to a review. In one embodiment, the method includes detecting a payment request from a vendor; generating a review based on the payment request; and, transmitting a reference to the review to a customer, wherein the reference provides a link to retrieve the review.
In another embodiment of the present invention, a computer readable medium having a computer readable program code contained therein for conducting a review includes computer readable program code for detecting a payment request from a vendor. The computer readable medium also includes computer readable program code for generating a review based on the payment request; and, computer readable program code for transmitting a reference to the review to a customer, wherein the reference provides a link to retrieve the review.
In another embodiment, the present invention is implemented in a review system having a processor and a memory coupled to the processor. The memory includes a vendor application and a customer application, wherein the vendor application is configured to receive a payment request from a vendor, and the customer application is configured to generate a review based on the payment request and transmit a reference to the review to a customer
Other features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description. It is to be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not limitation. Many changes and modifications within the scope of the present invention may be made without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be more readily understood by referring to the accompanying drawings in which:
FIG. 1 is a flow diagram illustrating the process of a customer ordering services using an online marketplace in accordance with one embodiment of the present invention.
FIG. 2 is a flow diagram illustrating the process of a vendor accessing and retrieving job information using the online marketplace in accordance with one embodiment of the present invention.
FIG. 3 is a flow diagram illustrating the process of the vendor retrieving payment using the online marketplace after providing services to the customer in accordance with one embodiment of the present invention.
FIG. 4 is a flow diagram illustrating the process of the online marketplace effecting a payment to the vendor in accordance with one embodiment of the present invention.
FIG. 5 is a flow diagram illustrating the process of the online marketplace sending out a message to the customer with a link to a review in accordance with one embodiment of the present invention.
FIG. 6 is a flow diagram illustrating the process of the customer using the online marketplace to retrieve the review referenced in the link sent in the process illustrated by FIG. 5 .
FIGS. 7 a - 7 g are screen shots of a user interface for the customer to place service requests.
FIGS. 8 a - 8 d are screen shots of a user interface for the vendor to access the vendor's account.
FIGS. 9 a - 9 b are screen shots of a user interface for the vendor retrieving payment for the vendor's services.
FIGS. 10 a - 10 b are screen shots of a user interface for the customer retrieving the review.
FIG. 11 shows a block diagram of an online marketplace application in accordance with one embodiment of the present invention.
Like numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a mechanism in a online marketplace for a service provider (“vendor”), who has provided service to a customer that has pre-paid for those services, to retrieve those funds from an “escrow” account. The vendor retrieves the funds based on a payment code that the customer gives to the vendor upon completion of the provision of the services. Once the payment code is entered, the vendor is paid and, simultaneously, the customer is e-mailed a link to a review form to provide feedback for the vendor. In one embodiment of the present invention, the link is a Universal Resource Locator (URL) to a web page on a website such as emove.com. When the customer clicks on the web page link in the review form, the customer will be taken to the website where the customer can provide feedback about the vendor (without having to first login to the website). Once the customer has submitted feedback, the customer will be credited with a refund of transaction fees charged by the online marketplace.
FIG. 1 is a flow chart illustrating the process for a customer to request service be provided by a vendor, in accordance with one embodiment of the present invention. The provision of the service is referred to as a “job” generally. In the presented example, the customer desires to contract for moving services to move furniture and boxes at a location in Grafton, N. Dak. As will be apparent from the description contained herein, the system in the example applies to other types of services, whether or not they are related to moving services. For example, services including, but not limited to, plumbing services, painting services, cleaning services, and gardening services, may be contracted for using the system.
In step 102 , the customer enters the general geographical area(s) where the service, or job, is to be performed. The system uses this information to select from a list of vendors that provide services in the entered geographical area(s) to be displayed, as discussed below. FIG. 7 a is a window displaying that the customer has entered “Grafton” in the “City:” field, and “ND” in the “State:” field, in the “Moving From:” section, indicating that the customer is requesting moving services only within the Grafton, N. Dak. region. The customer proceeds to the next step by clicking on the “LET'S GET STARTED” button, and operation continues with step 104 .
In step 104 , the customer enters the date on which the service is to be provided, and the type(s) of service desired. FIG. 7 b illustrates two services typically associated with moving help: loading/unloading help and driving help. In one embodiment, the services listed are based on previously defined categories of services. In another embodiment, the services listed include all the services offered by the vendors in the general geographical area previously entered by the customer. The customer can then proceed to the next step of the process as shown in FIG. 7 b and subsequent figures by clicking on the “NEXT STEP” button.
In step 106 , the system displays the vendors matched by the system that provide loading/unloading service in the Grafton, N. Dak. area. FIG. 7 c illustrates a window that lists two service providers: “Jane's Help” and “One Helpful Guy”, with rating information based on evaluations that have been previously submitted by other customers. The customer may receive more information by selecting the “more info . . . ” link, and read the received reviews for each vendor by selecting the “reviews . . . ” link for the appropriate vendor. In the example shown in FIG. 7 c , the customer has selected “Jane's Help” as the vendor to which the customer wishes to submit a request for moving help.
In step 108 , the customer is presented with a legal agreement outlining the terms and conditions under which access to the system is being provided for the customer to engage the services of the vendor. In another embodiment, the terms and conditions may also include the terms and condition for the selected vendor. FIG. 7 d illustrates a window with a summary of the terms and condition for emove.com, with a “user agreement” link for the customer to retrieve a detailed version of the terms and conditions. Operation continues with step 110 when the customer clicks on the “I AGREE” button.
In step 110 , the customer enters detailed job information, including the specific address where the service is to be provided, including the zip code; a phone number; the number of hours of service desired; and an elaboration of the service being requested. The customer may also provide other details, including but not limited to a preferred time of day for the provision of the service; major cross-street of the location; and other special needs or information. FIG. 7 e illustrates an exemplary window where the customer has entered the address of “123 N. Nowhere Ave.”; a zip code of “12345”; a phone number of “555-555-1234”; a description of “Moving furniture and boxes”; and a desired time period of “3” hours.
In step 112 , the customer is presented with a summary of the order to verify the details of the job and also requested to enter billing information. FIG. 7 f illustrates a window where the customer has entered his name (“John Doe”); address (“123 N. Nowhere Ave., Grafton, N. Dak., 12345”; e-mail address (“[email protected]”); payment (“Visa”); card number (“1111-1111-1111-1111”); and expiration date of the credit card (“January 2004”). The customer places the order by clicking on the “PLACE ORDER” button. The sequence contained in steps 102 to 112 illustrates one way for the system to receive a job request from a customer. For example, more or less information may be requested by the system depending on whether more or less screens, respectively, is presented to the customer.
In step 114 , the system presents the customer with a confirmation of the job request and other pertinent information, including instructions to provide the vendor with a payment code that will allow the vendor to retrieve remuneration, as described below, once the job has been completed. In addition, the vendor is contacted with notification that a new job request has been received for the vendor's services. For example, an e-mail informing the vendor that a new job request for the vendor's services has been received may be sent to the vendor. FIG. 7 g illustrates a sample confirmation window, displaying the payment code and the payment mechanism with which the customer will be charged when the vendor accepts the job request. In another embodiment, the customer is not presented with a payment code nor is the customer charged any fees until the vendor has accepted the job request. In yet another embodiment, the customer may be charged a fee as a deposit before the job request is presented to the selected vendor.
The contents of an exemplary e-mail that may be sent to a vendor notifying the vendor of a job request is as follows:
To: [email protected]
From: [email protected]
Subject: You have an eMove job. Respond within 24
hours.
Body:
A customer has requested service from you.
Job # 47690
Load or Unload Help
2-man crew - we can do the whole load/unload for you!
Where & When:
Grafton, ND 12345
3 hour on Wednesday, December 25, 2002
Customer notes:
Move furniture and boxes.
Accept this job:
http://serviceprovider.emove.com/acceptjob?id=47690&vi
d=232&[email protected]
Reject this job:
http://serviceprovider.emove.com/rejectjob?id=47690&vi
d=232&[email protected]
... or go to http://www.emove.com/serviceprovider and
choose to either accept or reject this job. If you
accept this job, it will be scheduled and you will be
given more details. If you do not accept it within 24
hours, it will be counted as a rejection. Rejecting
too many jobs will result in bad karma!
Regards,
eMove Moving Help
End
As shown in the text above, the e-mail is sent to the vendor from emove.com, with links for the vendor to accept (“http://serviceprovider.emove.com/acceptjob?id=47690&vid=232&[email protected]”) or reject (“http://serviceprovider.emove.com/rejectjob?id=47690&vid=232&[email protected]”) the job request without having to login to the emove.com website. As suggested in the text of the e-mail, and as described below, the vendor may also view and accept the job on the website once the vendor accesses the vendor's account.
FIG. 2 is a flow chart illustrating the process for the vendor to access the vendor's account and retrieve job information, including accepting or denying new job requests, viewing currently scheduled jobs, viewing the vendor's ratings, or requesting payment for completed jobs, according to one embodiment of the present invention.
In step 202 , the vendor logs onto the website. FIG. 8 a illustrates a window where the vender provides his login information, including a user identifier (“Email address”) and a password (“Password”), and submits that information for validation to enter the site by clicking on the “SIGN IN” button. If a vendor has not previously signed-up as a service provider for emove.com, then the vendor can select the “Sign up for an account” link to create a new account.
In step 204 , the vendor has successfully logged onto the website and is presented with the vendor's account information. FIG. 8 b illustrates the window that is displayed to the vendor after the vendor has logged in. The display includes any new job requests the vendor has received (“New work requests”), which in this case is job #47690; any scheduled jobs to which the vendor has agreed to provide service (e.g., job #47587), and a link to a list of jobs that the vendor has completed (“Completed jobs”). The display also provides a summary of each of the jobs.
The display shown in FIG. 8 b also includes a summary of the vendor's current rating based on comments and feedback received from customers for which the vendor has previously provided services, including a graphic that displays the numerical summary rating using stars. In the example, as part of a customer's feedback, the customer may award a vendor a numerical rating ranging from “1” to “5,” with a rating of 1 being the worst rating and the rating of 5 being the best rating. The system will use an average of the numerical ratings of all customer responses to produce the number shown in the display. A link to the list of comments is also shown (“View comments . . . ”).
Continuing to refer to FIG. 8 b , and specifically the “New work requests” section listing a new job #47690 that was previously entered by the customer, the vendor can choose to accept or deny the new job request by clicking on the “Accept” or “Reject” buttons, respectively. If the vendor accepts the job request, the customer is sent an e-mail. If the vendor rejects the job request, the customer will receive an e-mail with a message that the vendor has rejected the service request. The customer may then be provided with a link in the e-mail to go directly to the service provider selection page—i.e., FIG. 7 c , to choose a new vendor to whom the customer will submit a service request.
The contents of an exemplary e-mail sent to the customer when the vendor accepts the job request is as follows:
To: [email protected]
From: [email protected]
Subject: Load or Unload Help for 12/25/02 has been
accepted
Body:
******************************************************
Please do not reply directly to this message - use the
contact information below.
******************************************************
Dear John,
Jane's Help is happy to accept your request for
Load or Unload Help on Wednesday, December 25, 2002.
Please note that you have now pre-paid for 3
hours of our service and eMove has charged $110.00 on
your card for this job. We look forward to discussing
your needs in more detail. If you do not hear from us
within 24 hours, please call us at the phone number
below.
After the service is completed to your
satisfaction, we will need the Payment Code that
appears below from you to make sure we are paid for
this work.
----------------------------
*** Payment Code: 818826 ***
----------------------------
Critical Information:
- Do not give the Payment Code out until after
the job is completed.
- There will be no need to pay with cash or
check, unless you exceed the amount of pre-paid
service.
- If you have further questions about the Moving
Help process, please go to
http://www.emove.com/mh/faq.html
- Questions that we can't answer should be
directed to [email protected] (include the job
number, which is #47690)
Thanks for choosing us as your service provider.
We look forward to serving you.
Regards,
Jane Juniper
Jane's Moving Help
Contact info:
Phone: 555-555-4321
Email: [email protected]
*** This email has been sent to you from eMove Moving
Help on behalf of Jane's Help. ***
End
As shown in the text above, the e-mail is sent to the customer from emove.com on behalf of the vendor, with contact information for the vendor listed at the end of the e-mail, which allows vendors that do not have electronic mail capabilities to provide services as the system sends the e-mails for coordinating the transaction. In this case, however, the vendor is contactable by e-mail.
The e-mail also notifies the customer that the customer has now pre-paid for the services as a vendor has accepted the job request. The funds are held in escrow pending completion of the scheduled job, and will be retrieved by the vendor using the payment code as described herein. Thus, practically, the customer has prepaid for the services, with the funds provided by the customer being held by emove.com until proof of the being completed is received.
Returning to FIG. 2 , in step 206 , the vendor accepts the new job request for job #47690 and is presented with a confirmation of the job being scheduled for performance by the vendor. FIG. 8 c illustrates an exemplary window displayed to the vendor listing the details of job #47690, which contains information previously entered by the customer—i.e., FIGS. 7 a - 7 g . As further discussed herein, this display is also where the vendor will enter the payment code provided by the customer once the vendor has performed the services for which the vendor is contracted.
In optional step 208 , the vendor is presented with an updated account display with the now accepted job request for job #47690 being listed under the “Scheduled jobs” section. FIG. 8 d illustrates the updated account display for the vendor. Listed along each job is a link to the detailed information for the job (“View”), which the vendor can access to retrieved detailed information—such as the one shown in FIG. 8 c.
Upon the scheduled day(s) of the service, the vendor performs the contracted for service and, upon completion of the job, the customer provides the vendor with the payment code. In this example, as contained in the above e-mail, the payment code is “818826.” Once the vendor receives the payment code from the customer, remuneration may be retrieved by the vendor by going to the emove.com website. As described below, the present invention provides for “simultaneous” payment retrieval by the vendor and transmittal of a review request to the customer.
FIG. 3 is a flow chart illustrating the process for payment retrieval by the vendor and transmission of the link to the review being sent to the customer in accordance with one embodiment of the present invention. As described, this process occurs when the vendor has completed the job for the user and the user has provided the vendor with a payment code. The vendor is then ready to retrieve the funds associated with the payment code.
In step 302 , the vendor logs onto the website and selects the job for which the vendor desires to receive remuneration by selecting on the “View” link for the appropriate job (e.g., job #47690) in FIG. 8 d . The login process is described above in relation to FIG. 8 a and the display of the (scheduled) jobs for which the vendor may enter payment is described above in relation to FIGS. 8 b and 8 c.
Once the vendor has navigated to the job detail screen as shown in FIG. 8 c , the vendor may enter the payment code and then clicks on the “GET PAID” button to submit the code. In FIG. 9 a , the vendor has entered the payment code (“818826”).
In step 306 , once the payment code is verified, the system transfers the funds to the vendor. As shown in FIG. 9 b , the vendor has previously indicated that the preferred payment method for the vendor is an electronic payment system provided by PayPal, Inc. In addition, as further detailed below, the system transmits a link to a review request for the job to the customer in an e-mail.
FIG. 4 illustrates the process under which the vendor is sent payment in accordance with one embodiment of the present invention, where, in step 402 , the system detects that the vendor is requesting payment based on the submission of the payment code. In step 404 , the system determines the preferred payment method as previously selected by the vendor, which may include, but is not limited to, electronic payment systems such as PayPal, Inc.; electronic fund transfers to the vendor's bank account; or a payment to a credit card account of the vendor. It is to be noted that the payment may be made in a variety of mechanisms. Once the payment mechanism has been determined, the system effects payment in step 406 .
FIG. 5 is a flow chart illustrating the process of the system sending an e-mail to the customer once the vendor has requested payment in accordance with one embodiment of the present invention, where, starting in step 502 , it is detected that the vendor has retrieved payment using the payment code for the job. In step 504 , it is determined whether the job has been completed, and operation proceeds with step 506 if the job has been completed. In step 506 , it is determined whether the job is unreviewed, and operation proceeds with step 508 if the job has not been reviewed. If it is determined that the job is not completed (step 504 ) or if it is determined that a review has already been submitted for the job associated with the payment code (step 506 ), operation will end and no message will be sent to the customer.
In step 508 , if the job is completed and no review has been submitted for the job, then, in the preferred embodiment, the system will construct and transmit an e-mail to the customer with a link to a review for reviewing the vendor with respect to the particular job. The system checks for these conditions to prevent a customer from completing a review if the customer has already submitted a review for the job; or if the job has not been “completed,” with the definition of a job being completed being equated to the vendor retrieving payment. In another embodiment, the review may be sent to the customer in the body of the e-mail, in which case the e-mail contains code that allow an e-mail reader program to retrieve and display the review automatically. For example, the e-mail may contain hypertext markup language (HTML) code that references and displays the review. As defined by the present invention, there is no distinction made between code that “references” the review and code that displays the review. Thus, the code for the link to the review could include the code to display the review itself, such that there would be no need to retrieve any further data from the system to display the review.
The contents of an exemplary e-mail message sent to the customer from emove.com is shown below:
To: [email protected]
From: [email protected]
Subject: Get an eMove automatic refund - your comments
wanted!
Body:
Thank you for using eMove Moving Help. Your
Service Provider has been paid.
Moving families want to hear about your Load or
Unload Help experience with Jane's Help. The
transaction fee of $3.95 will automatically be
refunded to your credit card upon your rating. It
takes only 30 seconds!
To rate Jane's Help, click on the link below or
cut and paste it into your Web browser:
http://movinghelp.emove.com/ratejob?cid=90542-
12345&[email protected]&id=47690
To view a receipt of your Moving Help order, go
to:
http://movinghelp.emove.com/receipt?cid=90542-
12345&[email protected]&id=90542
Regards,
eMove Moving Help
www.emove.com
End
In the e-mail message shown above, the link to access the review (“http://movinghelp.emove.com/ratejob?cid=90456-12345&[email protected]&id=47690”) includes the customer identifier (“cid=90456-12345”), which includes the order number (“90456”) and zip code of the customer (“12345”); the e-mail address of the customer (“[email protected]”); and the identifier of the job for which the review that is to be retrieved is associated (“id=47690”). The e-mail message also include the link to view a receipt of the job (“http://movinghelp.emove.com/receipt?cid=90542-12345&[email protected]&id=90542”) includes the same information as the link to access the review, with the difference that the identifier relates to the order number versus the job number. A sample receipt is shown in FIG. 7 g , which is discussed above. It should be noted that the link to the review may be of various forms, and is not limited to the specific format or type of the uniform resource locator (URL) shown above.
The present invention, by immediately contacting the customer as soon as the vendor retrieves payment for the vendor's services, provides for the maximum likelihood that the customer will submit a review for the service provided by the vendor. The inclusion of a direct link to the review form, without the need for the customer to login (i.e., enter a username and password), locate, and then retrieve the review for the particular job that was performed, reduces the number of operations that the user must engage in to provide feedback down to a single click on the link to the review. Also, as discussed herein, there is a financial incentive for the user to provide feedback. Other incentives, financial or otherwise, may be presented to the customer and the particular form of compensation should be not limited to the ones described herein.
FIG. 6 is a flow chart illustrating the process where the customer is retrieving the review using the link provided in the e-mail. In step 602 , the system detects a request by the customer to retrieve the review. Based on this request, a series of conditions are tested before the review is transmitted. In the embodiment where the e-mail sent to the customer contains the actual review, the conditions are tested before the customer's response to the review is accepted. These checks are necessary as a review should only be sent to the customer (or the response to the review accepted) if a job has been completed by the vendor (based on detection of the payment request), and if no evaluation has been previously completed by the customer.
It is first determined in step 604 whether the job associated with the review requested by the customer has been cancelled, thereby making any results of the review inapplicable. If the job has not been cancelled, operation continues with step 606 , where it is determined if the job is actually pending and not a “completed” job. If the job is determined to not be still pending, operation continues with step 608 , where it is determined if payment has been retrieved by the vendor. If the payment has been retrieved, then operation continues with step 610 , where it is determined if a review has already been submitted for the job associated with the review. If the job has been paid, operation continues with step 612 , where the review is presented to the customer. In the embodiment where the review has been previously transmitted, the response to the review is accepted at this point.
If at anytime none of the conditions described above are met such that sending the review (or receiving the response to the review) is valid (e.g., sending a review or receiving the response for a job that was never completed), the system will proceed with step 614 , where the request to retrieve the review (or to send the response) is denied. The system may display an error message with the reason the review is not being transmitted (or the response is not being accepted).
FIG. 10 a illustrates a window displaying a review configured in one embodiment of the present invention, where a customer may provide feedback by assigning a numerical rating to the vendor as well as provide written comments. The review also inquires as to how many hours out of the total of the contracted order was actually performed. When the customer has completed the review, the customer may click on the “submit” button to submit the feedback. In the example that is provided, the customer may assign a rating between 1 (lowest rating) and 5 (highest rating).
Once the response to the review is received from the customer, the vendor's rating information is updated. In addition, the refundable order handling fee is refunded to the customer, preferably using the same payment mechanism with which the customer originally paid for the services. For example, if the customer paid for the services with a credit card, the refund would be applied to the same credit card. FIG. 10 b illustrates the window displaying a “Thank You” message to the customer once the review has been submitted by the customer.
Other actions may be generated by the system based on the ratings received in the review from the customer. For example, if there is an unusually low rating given by the customer, an e-mail may be sent to the customer service department of the company operating the marketplace (i.e., e-move.com) to follow-up with the customer, as well as an e-mail to the vendor notifying them of the low rating and encouraging the vendor to follow-up with the customer as well. Conversely, a high rating would warrant a congratulatory e-mail to the vendor from the company operating the marketplace.
FIG. 11 is a block diagram of an online marketplace application in accordance with one embodiment of the present invention, which is software executing on an emove.com computer server. An online marketplace application 1102 contains four primary software components: a customer application 1104 , a vendor application 1106 , an administrative application 1108 , and an underlying layer 1110 . Customer application 1104 allows the customer to navigate through the marketplace with the functionality of the processes described in FIGS. 1 , 5 and 6 and provides the customer interface as described above in FIGS. 7 a - 7 g , and 10 a - 10 b . Thus, customer application 1104 provides the functionality of selecting and paying for a service from a particular vendor; and after the service is completed, customer application 1104 provides the functionality for accepting feedback and comments from the customer regarding the vendor. It also allows a customer to review the transactions that have been paid for before and after a job is completed.
Vendor application 1106 provides functionality for vendors to complete necessary tasks such as those described in FIGS. 2-4 for the online marketplace. Initially, vendor application 1106 processes vendors being added to the lists maintained by the host. Vendor application 1106 handles the login process for vendors entering the marketplace and processes payment codes entered by a vendor to transfer money from an escrow account to the vendor's account. Vendor application 1106 also processes scheduling services for the vendors and provides schedules to vendors. Vendor application 1106 provides the user interfaces describe in FIGS. 8 a - 8 c and 9 a - 9 b.
Administrative application 1108 allows an administrator of the online marketplace to oversee the entire application and perform basic administrative functions. A few examples of this include assigning a particular city to a service area or adding a new category of services to the services offered in the marketplace. It also allows an administrator to access data for analysis and creating statistics on customer behavior. Underlying layer 1110 provides the groundwork or foundation for the applications to function. For example, it maps the database containing vendor and customer information, needed by the applications to operate, and determines the overall look and feel of the online marketplace system.
Although the description of the invention is directed to vendors primarily as “service” providers, the mechanisms described above apply to vendors providing “goods” in addition to or instead of services. Thus, the “job” number would be related to a particular purchase of goods and the time would be related to the time of delivery.
Moreover, it is to be noted that although the description contained herein describes an exemplary series of steps executed in a particular order in accordance with one embodiment of the present invention, the sequence of operations may be altered or certain steps may be combined or cancelled in other embodiments of the present invention. Further, certain steps may be further divided in these other embodiments.
The system may also be implemented using a variety of technologies other than the client-server web system described herein. For example, the system may be implemented using a telephone system, where vendors may review job requests; respond to job requests; request payments; retrieve their customer provided ratings and feedback; and otherwise perform the same types of vendor operations using a telephone system as would be performed using the emove.com website. In addition, customers may receive a listing of vendors; review and select vendors for job requests; provide payment information; revise/review job requests; provide feedback and review for a completed job; and otherwise perform the same types of customer operations using a telephone system as would be performed using the emove.com website.
The embodiments described above are exemplary embodiments of the present invention. Those skilled in the art may now make numerous uses of, and departures from, the above-described embodiments without departing from the inventive concepts disclosed herein. Accordingly, the present invention is to be defined solely by the scope of the following claims. | A method for conducting a review including the step of detecting a payment request from a vendor; generating a review based on the payment request; and, transmitting a reference to the review to a customer, wherein the reference provides a link to retrieve the review. A system for performing the method is also described. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to connections between rotary drives and rotary loads, wherein, due to parallel misalignment between the axes of the drive and load, such as, for example, orbital movement of the load axis during rotation, the drive and the load require a flexible connection. More particularly, the invention relates to a flexible-shaft-type connection between the drive and load that carries bending stresses during operation and especially to a means for isolating the end portions of the shaft at the point where the attachment is made to the rotary drive or rotary load from the stresses that occur due to the bending moment applied to the shaft.
One particular application where such flexible shafts are used is in connection with progressing cavity, positive displacement rotary pumps, such as the pumps described in my U.S. Pat. Nos. 3,512,904 and 3,938,744 (hereinafter referred to as "Allen" devices, or pumps). These pumps have a rotor with an exterior helical surface that engages the surrounding interior helical surface of the stator, the rotor surface having one more thread than the stator surface and a lead twice that of the stator surface. Thus, the stator surface and the rotor surface define therebetween sealed pumping cavities that are axially advanced as the rotor rotates and at the same time orbits in the same direction at two or more times the rate of its rotation. For a more complete description of Allen pumps of this type, reference is made to my aforesaid U.S. Pat. No. 3,512,904.
Another class of rotary helical devices or pumps that utilize flexible coupling shafts to advantage is the class that includes the well-known Moineau-type device as disclosed, for example, in U.S. Pat. No. 1,892,217. Typical examples of the use of flexible shafts for Moineau-type pumps are shown in U.S. Pat. Nos. 2,028,407; 2,456,227; and 3,612,734. The devices shown use metal shafts or metal cables.
More recently, flexible shafts formed of an engineering grade plastic, such as an acetal homopolymer known commercially as "DELRIN", have been used as disclosed in my U.S. Pat. No. 3,938,744. The connection of the flexible shaft to the rotary drive shaft and to the rotor can be accomplished in several ways, one method being, where space permits, radial flanges or hubs. Since it is usually not practical to form the shaft and hubs as an integral unit, it is often desirable to secure the hub or hubs to the shaft by bonding, such as, for example, in the case of engineering grade plastics, by spin welding.
During operation, however, the flexing of the shaft and the sharp change in flexibility at the joint between the shaft and built-in support collar or hub produce concentrated stresses in the shaft at the edge of the joint. This stress concentration in the bonding zone increases the danger of failure during use and shortens the effective life of the shaft.
The device of the present invention, however, reduces the difficulties indicated above and affords other features and advantages heretofore not obtainable.
SUMMARY OF THE INVENTION
It is among the objects of the invention to provide an improved, flexible-shaft-type coupling between a rotary drive and a rotary load wherein the axes of the drive and load are in parallel misalignment during operation.
Still another object is to relieve stresses occurring at the joint between a flexible shaft and a radial flange, or hub, at the end, or ends, of the shaft used to connect the ends of the shaft to a rotary drive or a rotary load, wherein the shaft flexes during operation to cause bending moments that result in stress concentration at the ends of the shaft.
Still another object is to provide an improved, flexible-shaft-type coupling means between a rotary drive and an orbital rotor for a progressing cavity, positive displacement rotary pump.
These and other objects are accomplished by the device of the present invention wherein a novel, flexible shaft assembly is used to connect a rotary drive to a rotary load, the shaft being subject to flexure during operation that results in stress concentrations at the end, or ends, of the shaft. In accordance with the invention, the shaft is provided with a radial hub on at least one end thereof for connecting the respective end to either the rotary drive or the rotary load. In order to relieve the joint between the shaft and the hub from stresses of the type described, an annular stress relief member is mounted on the shaft inwardly of and secured to the radial flange. The stress relief member is tightly positioned around the underlying surface portion of the shaft to provide a fixed-end, cantilever-type support for the shaft, whereby bending stresses occurring due to the bending moment produced by beam-type shaft flexure are transmitted to the stress relief member to reduce stress at the junction of the shaft and the radial flange.
In the preferred form, the shaft is connected at one end to a rotary drive having a fixed axis of rotation and extends through a generally tubular rotor so that a shaft hub at the opposite end is connected to the rotor which is adapted for both rotary and orbital movement.
Also, in the preferred form, the flexible shaft and the hub, or hubs, are formed of an engineering grade plastic and the hub, or hubs, are bonded to the flexible shaft, such as by spin welding. Prior to the bonding operation, the stress relief member is pressed onto the shaft inwardly of its final position prior to the bonding operation. After the bonding operation, the stress relief member is forced axially outwardly on the shaft into engagement with the hub. Then the hub and the stress relief member are tightly secured to one another and also to the drive hub, such as by nuts and bolts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a progressing-cavity, positive-displacement rotary pump, utilizing the flexible shaft assembly of the invention;
FIG. 2 is an elevational view of the rotary pump of FIG. 1 with parts broken away and shown in section for the purpose of illustration;
FIG. 3 is a broken sectional view on an enlarged scale of the flexible shaft assembly of the rotary pump of FIGS. 1 and 2 and embodying the present invention;
FIG. 4 is a sectional view taken on line 4--4 of FIG. 3; and
FIG. 5 is a sectional view taken on the line 5--5 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purpose of illustration, the invention will be described herein in connection with its use in a progressing cavity Allen-type pump designed for pumping liquid and liquid slurries. The pump is of the larger variety, such as might be used in municipal sewage facilities where high volume output is required. The pump shown and described is capable of pumping 150 gallons per minute at 500 rpm. Liquid is received by the pump through an inlet pipe (not shown) with a suitable flange fitting and is exhausted through an outlet (not shown) connected to the front end of the pump. The pump comprises a main housing assembly 10, a shaft housing assembly 20, a stator assembly 30, a rotor assembly 40, and a coupling shaft assembly 50, embodying the invention.
The main housing assembly 10 has a body in the form of a steel casting with radial flanges 11 and 12 on each end. The radial flange 12 fits against the shaft housing assembly 20 and is secured thereto by bolts 13 to fasten the two housing assemblies 10 and 20 together. The body defines an inlet cavity 14 and an inlet throat 15 communicating with the inlet cavity 14. The inlet throat 15 is defined, in part, by an inlet flange 16 with four symmetrically spaced bolt holes 17, as indicated in FIG. 1, used to secure an inlet pipe to the pump. At the bottom of the inlet cavity 14 is a pipe plug 18 that may be used for draining and cleaning the pump.
The shaft housing assembly 20 also has a body in the form of a steel casting that serves as a bearing mount for a rotary drive shaft 21. The shaft 21 is journaled in a conventional manner in a pair of bearing assemblies 22 and 23, supported in the shaft housing assembly 20, as indicated in FIG. 2. The outer, or rearward end, of the shaft 21 has a key slot 24 that receives a conventional key 25 used to connect the shaft 21 to a power source, such as a diesel engine (not shown) for driving the pump.
The shaft housing assembly 20 has a pair of openings 26 in opposite sides thereof used to facilitate access for cleaning and replacement of a packing gland assembly 27. A drive flange 28 is keyed to the inner end of the rotary drive shaft 21, the drive flange 28 being in the form of a split ring, with a key slot that cooperates with a Woodruff key 29 to key the drive flange 28 to the end of the shaft 21.
A stator assembly 30 with the rotor assembly 40 therein is located at the forward end of the main housing assembly 10. The stator assembly 30 includes a cylindrical casing 31, a radial outer flange 32 secured to the outer end of the cylindrical casing 31, and a radial inner flange 33 that bears against an annular ring 34, seated in an annular groove 35 in the cylindrical casing 31. The radial inner flange 33 thus urges the stator assembly into a position tightly seated against the main housing assembly 10, the flange 33 being secured to the radial flange 11 of the main housing assembly by nuts 36, threaded onto studs 37, which, in turn, are threaded into the radial flange 11.
A generally tubular stator 38, preferably formed of rubber or other resilient material, is bonded into the cylindrical casing 31. The stator 38 may be a molded, unitary element, or may be formed of two molded halves. The interior surface of the stator 38 defines helical threads that cooperate with the rotor in a manner described below.
The rotor assembly 40 includes a rotor 41, preferably formed of cast iron and which is located within the stator 38. The rotor 41 has an exterior helical surface with a generally elliptical form, the helical rotor surface having one more thread (i.e., two threads, in this instance) than the helical stator surface (the stator surface having one thread, in this instance). The helical rotor surface engages and cooperates with the helical stator surface to define sealed pumping cavities 42. Also, the threads of the rotor surface have a lead that is equal to the number of threads in the rotor surface times the lead of the helical surface of the stator 38 divided by the number of threads in the stator surface. As the rotor 41 rotates, its axis translates in an orbit circle about the axis of the rotary drive shaft 21, and the pumping cavities 42 are axially advanced. This function is described in my aforesaid U.S. Pat. No. 3,512,904.
The rotor 41 is of hollow construction and has a wall of generally uniform thickness along most of its axial length. The forward end portion 43 of the rotor 41, however, is considerably thicker and of a more solid construction. A rotor outer end plate 44 that covers the interior space of the rotor 41 is secured to the outer end of the rotor by bolts 45 that extend in an axial direction into threaded openings in the rotor. The inner end of the rotor 41 is sealed relative to the inlet cavity 14 by a rubber boot seal 46, with a radial flange 47 that fits against the end of the rotor 41 and is secured thereto by machine screws 48.
In accordance with the invention, the rotor 41 is coupled to the rotary drive shaft 21 by a coupling shaft assembly 50, the elements of which are molded of a strong engineering grade plastic, such as an acetal homopolymer or copolymer. The coupling shaft assembly includes a flexible cylindrical shaft 51, adapted to flex between its ends as necessary in order to accommodate the orbital movement of the rotor 41 in an orbit circle about the axis of the rotary drive shaft 21. As indicated, the coupling shaft assembly is located generally within the pump rotor 41. The outer and inner ends of the flexible shaft 51 are provided with radial hubs, 52 and 53, respectively, which are tightly bonded to the shaft. A preferred method of bonding the radial hubs 52 and 53 to the shaft 51 comprises forming the opposite ends of the shaft 51 with a conical taper (FIG. 3) and forming the hubs 52 and 53 with an opening have a matching conical taper, as indicated at 56 and 57. Accordingly, the hubs may be bonded to the shafts by spin welding, in accordance with spin welding techniques well-known to those skilled in the art.
As indicated above, the flexing of the shaft during pump operation would result, in the absence of the structure embodying the invention, in bending moments which, together with the means of support, cause a concentration of stress at the ends of the shaft at the zone of the bond between the shaft and the hubs 52 and 53. In order to reduce the stress, there are provided, in accordance with the invention, stress relief hubs 62 and 63 which are tightly seated against the radial hubs 52 and 53 and which are tightly fitted around the underlying surface portions of the shaft 51. The stress relief hubs 62 and 63 are then tightly secured, such as by bolts, to the radial hubs so that the fixed-end-type centilever support is provided by the stress relief hubs 62 and 63, rather than by the radial hubs 52 and 53. The radial hubs 52 and 53 thus are limited to carrying the torsional stress caused by torque applied through the hubs 53 and 52 to the flexible shaft 51 and to the rotor 41, respectively. In the embodiment shown, the stress relief hubs 62 and 63 are provided with axially projecting annular extensions 64 and 65. These are adapted to flex slightly and thus to provide a more gradual distribution of stress in transition between the portions of the shaft 51 where the greatest bending stress occurs and the more rigid portions of the stress relief hubs 62 and 63 beyond the inner ends of annular extensions 64 and 65.
Stress concentration factors as high as 2.5 or higher would occur at the edge of the spin welded joints 56 and 57, whereas, the axially projecting extensions 64 and 65 in hubs 62 and 63 flex slightly and effectively reduce the stress concentration factor to 1.5 or even to 1.2. This reduces the maximum shaft bending stress below the fatigue endurance limit of the material and thus extends the useful life of the flexible shaft 51.
Assembly
In the fabrication and assembly of the coupling shaft assembly 50 shown and described herein, it is desirable, after the shaft 51 and hubs 52 and 53 are formed with the respective conically tapered ends and openings, that the stress relief hubs 62 and 63 be pressed onto the flexible shaft 51 to approximately the positions illustrated in dashed lines in FIG. 3.
After the stress relief hubs 62 and 63 are preliminarily positioned on the flexible shaft 51, the radial hubs 52 and 53 are spin welded to tightly bond them to the shaft. The bolt holes 58 and 59 are formed in the radial hubs 52 and 53 before the bonding occurs. It should be noted, also, that no holes are formed initially in the stress relief hubs 62 and 63.
After the spin welding is completed, the stress relief hubs 62 and 63 are pressed axially outward to the positions shown in solid lines in FIG. 3. Then four threaded holes 66 are tapped in the stress relief hub 62 corresponding to the four holes 58 already formed in the radial hub 52 and the matching holes 67 are likewise drilled through the stress relief hub 63 corresponding to the holes 59 in the hub 53.
After this is accomplished, the coupling shaft assembly 50 is bolted to the drive flange 28 on the rotary drive shaft 21 using bolts 71 that extend through both the stress relief hub 63 and the radial hub 53. Then the rotor assembly 40 is placed within the stator 38 and the rotary drive shaft 21 is rotated until the openings in the rotor outer end plate 44 match the openings in the radial hub 52 and the stress relief hub 62. The rotor is then bolted to the coupling shaft assembly using machine screws 72.
After this, the boot seal 46 and flange 47 are bolted to the other end of the rotor 41.
The rotor and stator geometry and the mathematical relationships involved in their operation are described in detail in my U.S. Pat. No. 3,512,904 which is made a part hereof and incorporated by reference herein.
Typical dimensions for the helical positive displacement rotary pump illustrated herein are given in TABLE I below.
TABLE I______________________________________PumpDimension (Inches)______________________________________Eccentricity .3Cavity length 12.2Rotor major dia. 4.8Rotor minor dia. 3.6Rotor form length 16.5Stator major inside dia. 5.4Stator minor inside dia. 4.2Stator outside dia. 6.4Stator length 16.0Stator/cavity length ratio 1.3______________________________________
In the operation of the pump, shown and described, the drive torque is transmitted from the rotary drive shaft 21 to the rotor 41 through the coupling shaft assembly 50, the flexible shaft 51 flexing sufficiently during the pump operation to accommodate the orbital movement of the rotor. The flexing of the flexible shaft causes bending moments that result in concentration of stresses at the opposite ends thereof. With this construction, however, radial hubs 52 and 53 are relieved of the bending stresses by the stress relief hubs 62 and 63 and there is relatively little danger of failure occurring at the joint where the ends of the shaft 51 are bonded to the radial hubs 52 and 53. Furthermore, the slight flexing of extensions 64 and 65 on stress relief hubs 62 and 63 effectively reduces the stress concentration factor from about 2.5 or higher to 1.5 or even to 1.2.
While the invention has been shown and described with respect to a specific embodiment thereof, this is intended for the purpose of illustration, rather than limitation, and other modifications and variations of the specific embodiment herein shown and described will be apparent to those skilled in the art, all within the intended spirit and scope of the invention. Accordingly, the patent is not to be limited in scope and effect to the specific embodiment herein shown and described, nor in any other way that is inconsistent with the extent to which the progress in the art has been advanced by the invention. | A stress relief device for a flexible shaft used to connect a rotary drive to a rotary load, wherein the shaft flexes in response to loads that produce bending stresses during shaft rotation. The shaft has a radial flange, or hub, on at least one end for connecting the respective end to another radial flange on either the rotary drive or the rotary load. In order to relieve the joint between the shaft and the hub from the stress concentration that occurs due to flexure of the shaft while being supported in built-in fashion as a cantilever beam, an annular stress relief member is mounted on the shaft inwardly of and tightly secured to the radial flange, or hub. The specially designed stress relief member is tightly positioned around the underlying cylindrical surface portion of the shaft to provide a fixed-end cantilever-type support therefor so that bending stresses occurring due to shaft flexure are more gradually transmitted to and through the stress relief member to avoid stress concentration at the junction of the shaft and the radial flange, or hub. | 5 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 60/355,566, entitled “MODIFIED PITUITARY GLAND DEVELOPMENT IN OFFSPRING FROM EXPECTANT MOTHER ANIMALS TREATED WITH GROWTH HORMONE RELEASING HORMONE THERAPY,” filed on Feb. 7, 2002, the entire content of which is hereby incorporated by reference.
BACKGROUND
[0002] The present invention pertains to a plasmid-meditated gene supplementation to alter pituitary development, and to increase prolactin levels, in an offspring of a female subject. More specifically, the present invention pertains to administering to a female subject a nucleic acid expression construct that encodes growth hormone releasing hormone (“GHRH”) to alter the pituitary development and pituitary hormone secretion (e.g. prolactin) in the offspring from the female subject.
[0003] The pituitary gland is an important link between the nervous system and the endocrine system. The pituitary gland is known to release many hormones that affect growth, sexual development, metabolism (e.g. protein, lipid and carbohydrate), glucocorticoids and the reproductive system. The pituitary gland has also been shown to release hormones that affect bone growth and regulate activity in other hormone secreting glands. This invention relates a method for altering pituitary gland development in offspring from female subjects that have been treated with a nucleic acid construct that encodes a growth hormone releasing hormone (“GHRH”) or functional biological equivalent. The expression of the GHRH or biological equivalent thereof is regulated by a tissue specific promoter (e.g. a myogenic promoter). When female subjects are treated with the nucleic acid construct that encodes GHRH, many physiological changes occur in the female subject directly. However, when female subjects are treated with the GHRH construct prior to, or during a gestation period, the offspring from these treated female subjects undergo similar physiological changes. For example, the subsequent expression and ensuing release of GHRH or biological equivalent thereof by the modified cells in the female subject results in the altered development of the pituitary gland in their offspring. Additionally, hormones secreted by the pituitary gland are increased in offspring from treated female subjects when compared to the offspring from control treated female subjects. More specifically, the pituitary gland is increased in sized and the levels of the multi functional hormone prolactin is elevated utilizing this method.
[0004] The pituitary gland has two distinct parts, the anterior and the posterior lobes, each of which releases different hormones. The pituitary gland appears to be subservient in part to the hypothalamus. Pituitary gland development, including regulation and differentiation of somatotrophs, depends upon paracrine processes within the pituitary itself and involves several growth factors and neuropeptides. Secretion of growth hormone (“GH”) is stimulated by the natural GH secretagogue, called growth hormone releasing hormone (“GHRH”), and inhibited by somatostatin (“SS”). The central role of growth hormone (“GH”) is controlling somatic growth in humans and other vertebrates, and the physiologically relevant pathways that regulate GH secretion from the pituitary are well known. For example, the GH production pathway is composed of a series of interdependent genes whose products are required for normal growth. The GH pathway genes include: (1) ligands, such as GH and insulin-like growth factor-I (“IGF-I”); (2) transcription factors such as prophet of pit 1, or prop 1, and pit 1: (3) stimulatory and inhibitory factors, such as growth hormone releasing hormone (“GHRH”) and somatostatin (“SS”), respectively; and (4) receptors, such as GHRH receptor (“GHRH-R”) and the GH receptor (“GH-R”). These genes are expressed in different organs and tissues, including but not limited to the hypothalamus, pituitary, liver, and bone. Effective and regulated expression of the GH pathway is essential for optimal linear growth, as well as homeostasis of carbohydrate, protein, and fat metabolism. GH synthesis and secretion from the anterior pituitary is stimulated by GHRH and inhibited by somatostatin, which are both hypothalamic hormones. GH stimulates production of IGF-I, primarily in the liver, and other target organs. IGF-I and GH, in tuni, feedback on the hypothalamus and pituitary to inhibit GHRH and GH release. GH elicits both direct and indirect actions on peripheral tissues, the indirect effects being mediated mainly by IGF-I.
[0005] The immune function is modulated by IGF-I, which has two major effects on B cell development: potentiation and maturation, and as a B-cell proliferation cofactor that works together with interleukin-7 (“IL-7”). These activities were identified through the use of anti-IGF-I antibodies, antisense sequences to IGF-I, and the use of recombinant IGF-I to substitute for the activity. There is evidence that macrophages are a rich source of IGF-I. The treatment of mice with recombinant IGF-I confirmed these observations as it increased the number of pre-B and mature B cells in bone marrow. The mature B cell remained sensitive to IGF-I as immunoglobulin production was also stimulated by IGF-I in vitro and in vivo.
[0006] The production of recombinant proteins in the last 2 decades provided a useful tool for the treatment of many diverse conditions. For example, recombinant GH administration has been used to treat GH-deficiencies in short stature children, or as an anabolic agent in burn, sepsis, and as well as in the elderly and AIDS patients. However, resistance to GH action has been reported in malnutrition and infection. Long-term studies on transgenic animals and in patients undergoing GH therapies have shown no causal correlation between GH or IGF-I therapy and cancer development. GH replacement therapy is widely used clinically, with beneficial effects, but therapy is associated several disadvantages: GH must be administered subcutaneously or intramuscularly once a day to three times a week for months, or usually years; insulin resistance and impaired glucose tolerance can occur; accelerated bone epiphysis growth and closure has been observed in pediatric patients (Blethen, S. L., et al. 1996).
[0007] In contrast, essentially no side effects have been reported for recombinant GHRH therapies. Extracranially secreted GHRH, as mature peptide or truncated molecules (as seen with pancreatic islet cell tumors and variously located carcinoids) are often biologically active and can even produce acromegaly (Esch, et al., 1982; Thorner, et al., 1984). Administration of recombinant GHRH to GH-deficient children or adult humans augments IGF-I levels, increases GH secretion proportionally to the GHRH dose, yet still invokes a response to bolus doses of recombinant GHRH (Bercu and Walker, 1997). Thus, GHRH administration represents a more physiological alternative of increasing subnormal GH and IGF-I levels (Corpas, et al., 1993).
[0008] GH is released in a distinctive pulsatile pattern that has profound importance for its biological activity (Argente, et al., 1996). Secretion of GH is stimulated by the GHRH, and inhibited by somatostatin, and both are hypothalamic hormones (Thorner, et al., 1995). GH pulses are a result of GHRH secretion that is associated with a diminution or withdrawal of somatostatin secretion. In addition, the pulse generator mechanism is timed by GH-negative feedback. The endogenous rhythm of GH secretion becomes entrained to the imposed rhythm of exogenous GH administration. Effective and regulated expression of the GH and insulin-like growth factor-I (“IGF-I”) pathway is essential for optimal linear growth, homeostasis of carbohydrate, protein, and fat metabolism, and for providing a positive nitrogen balance (Murray, et al., 2000). Numerous studies in humans, sheep or pigs showed that continuous infusion with recombinant GHRH protein restores the normal GH pattern without desensitizing GHRH receptors or depleting GH supplies as this system is capable of feed-back regulation, which is abolished in the GH therapies (Dubreuil, et al., 1990). Although recombinant GHRH protein therapy entrains and stimulates normal cyclical GH secretion with virtually no side effects, the short half-life of GHRH in vivo requires frequent (one to three times a day) intravenous, subcutaneous or intranasal (requiring 300-fold higher dose) administration. Thus, as a chronic treatment, recombinant GHRH administration is not practical.
[0009] Wild type GHRH has a relatively short half-life in the circulatory system, both in humans (Frohman, et al., 1984) and in farm animals. After 60 minutes of incubation in plasma, 95% of the GHRH(1-44)NH2 is degraded, while incubation of the shorter (1-40)OH form of the hormone, under similar conditions, shows only a 77% degradation of the peptide after 60 minutes of incubation (Frohman, et al., 1989). Incorporation of cDNA coding for a particular protease-resistant GHRH analog in a gene transfer vector results in a molecule with a longer half-life in serum, increased potency, and provides greater GH release in plasmid-injected animals (Draghia-Akli, et al., 1999, herein incorporated by reference). Mutagenesis via amino acid replacement of protease sensitive amino acids prolongs the serum half-life of the GHRH molecule. Furthermore, the enhancement of biological activity of GHRH is achieved by using super-active analogs that may increase its binding affinity to specific receptors (Draghia-Akli, et al., 1999).
[0010] Extracranially secreted GHRH, as processed protein species GHRH(1-40) hydroxy or GHRH(1-44) amide or even as shorter truncated molecules, are biological active (Thorner, et al., 1984). It has been reported that a low level of GHRH (100 pg/ml) in the blood supply stimulates GH secretion (Corpas, et al., 1993). Direct plasmid DNA gene transfer is currently the basis of many emerging gene therapy strategies and thus does not require viral genes or lipid particles (Muramatsu, et al., 1998; Aihara and Miyazaki, 1998). Skeletal muscle is target tissue, because muscle fiber has a long life span and can be transduced by circular DNA plasmids that express over months or years in an immunocompetent host (Davis, et al., 1993; Tripathy, et al., 1996). Previous reports demonstrated that human GHRH cDNA could be delivered to muscle by an injectable myogenic expression vector in mice where it transiently stimulated GH secretion to a modes extent over a period of two weeks (Draghia-Akli, et al., 1997).
[0011] Administering novel GHRH analog proteins (U.S. Pat. Nos. 5,847,066; 5,846,936; 5,792,747; 5,776,901; 5,696,089; 5,486,505; 5,137,872; 5,084,442, 5,036,045; 5,023,322; 4,839,344; 4,410,512, RE33,699) or synthetic or naturally occurring peptide fragments of GHRH (U.S. Pat. Nos. 4,833,166; 4,228,158; 4,228,156; 4,226,857; 4,224,316; 4,223,021; 4,223,020; 4,223,019) for the purpose of increasing release of growth hormone have been reported. A GHRH analog containing the following mutations have been reported (U.S. Pat. No. 5,846,936): Tyr at position 1 to H is; Ala at position 2 to Val, Leu, or others; Asn at position 8 to Gln, Scr, or Thr; Gly at position 15 to Ala or Leu; Met at position 27 to Nle or Leu; and Ser at position 28 to Asn. The GHRH analog is the subject of U.S. patent application Ser. No. 09/624,268 (“the '268 application”), which teaches application of a GHRH analog containing mutations that improve the ability to elicit the release of growth hormone. In addition, the '268 application relates to the treatment of growth deficiencies; the improvement of growth performance; the stimulation of production of growth hormone in an animal at a greater level than that associated with normal growth; and the enhancement of growth utilizing the administration of growth hormone releasing hormone analog and is herein incorporated by reference.
[0012] U.S. Pat. No. 5,061,690 is directed toward increasing both birth weight and milk production by supplying to pregnant female mammals an effective amount of human GHRH or one of it analogs for 10-20 days. Application of the analogs lasts only throughout the lactation period. However, multiple administrations are needed. A co-pending disclosure regarding administration of the growth hormone releasing hormone (or factor) as a DNA molecule, such as with plasmid mediated therapy techniques has been disclosed (U.S. patent application Ser. No. 10/021,403).
[0013] U.S. Pat. Nos. 5,134,120 (“the '120 patent”) and 5,292,721 (“the '721 patent”) teach that by deliberately increasing growth hormone in swine during the last 2 weeks of pregnancy through a 3 week lactation resulted in the newborn piglets having marked enhancement of the ability to maintain plasma concentrations of glucose and free fatty acids when fasted after birth. In addition, the '120 and '721 patents teach that treatment of the sow during lactation results in increased milk fat in the colostrum and an increased milk yield. These effects are important in enhancing survivability of newborn pigs and weight gain prior to weaning. However, the '120 and '721 patents provide no teachings regarding administration of the growth hormone releasing hormone (“GHRH”) as a DNA form.
[0014] Prolactin is a single-chain protein hormone closely related to growth hormone. It is chiefly secreted by lactotrophs in the anterior pituitary. However, prolactin is also synthesized and secreted by a broad range of other cells in the body, most prominently various immune cells, the brain and the decidua of the pregnant uterus. Prolactin is also found in the serum of normal females and males. Prolactin secretion is pulsatile and also shows diurnal variation, with the serum concentration increasing during sleep and the lowest level occurs about 3 hours after waking. The secretion of prolactin is increased by stress and appears to be dependent upon a women's estrogen status.
[0015] The conventional view of prolactin is that the mammary gland is its major target organ, and stimulating mammary gland development along with milk production define its major functions. Although these views are true, such descriptions fail to convey an accurate depiction of this multifunctional hormone. For example, it is difficult to find a mammalian tissue that does not express prolactin receptors, and although the anterior pituitary is the major source of prolactin, the hormone is synthesized and secreted in many other tissues. Overall, several hundred different actions have been reported for prolactin in various species. Some of prolactin's major effects are summarized below.
[0016] Prolactin's major known functions are attributed with mammary gland development, milk production and reproduction. In the 1920's it was found that extracts of the pituitary gland, when injected into virgin rabbits, induced milk production. Subsequent research demonstrated that prolactin has two major roles in milk production:
Prolactin induces lobulo-alveolar growth of the mammary gland, wherein the alveoli are the clusters of cells in the mammary gland that actually secrete milk. Prolactin stimulates lactogenesis or milk production after giving birth. Prolactin, along with cortisol and insulin, act together to stimulate transcription of the genes that encode milk proteins.
The critical role of prolactin in lactation has been established by utilizing transgenic mice with targeted deletions in the prolactin gene. Female mice that are heterozygous for the deleted prolactin gene only produce about half the normal amount of prolactin, and fail to lactate after their first pregnancy.
[0019] Prolactin is also important in several non-lactational aspects of reproduction. For example, in some species (e.g. rodents, dogs, skunks), prolactin is necessary for maintenance of ovarian structures (i.e. corpora lutea) that secrete progesterone. Mice that are homozygous for an inactivated prolactin gene and thus incapable of secreting prolactin are infertile due to defects in ovulation, fertilization, preimplantation development and implantation. Prolactin also appears to have stimulatory effects in some species on reproductive or maternal behaviors such as nest building and retrieval of scattered young.
[0020] Prolactin also appears to elicit effects in the immune system. For example, the prolactin receptor is widely expressed by immune cells, and some types of lymphocytes synthesize and secrete prolactin. These observations suggest that prolactin may act as an autocrine or paracrine modulator of immune activity. Conversely, mice with homozygous deletions of the prolactin gene fail to show significant abnormalities in immune responses. A considerable amount of research is in progress to delineate the role of prolactin in normal and pathologic immune responses. However, the significance of these potential functions remains poorly understood.
[0021] Administering prolactin stimulating hormones, or prolactin agonists (U.S. Pat. Nos. 5,605,885; and 5,872,127) for the purpose of stimulating the immune system have been reported. The U.S. Pat. No. 5,872,127 (“the '127 patent”) filed by Cincotta in 1999 discloses methods for treating a disorder of the immune system or an immunodeficiency state that comprise the steps of administering to a patient an effective amount a serotonin agonist and at a dopamine agonist, where the combination of the serotonin agonist and the dopamine agonist are present in an amount effective to treat a patient's immuno-compromised condition. The administration of each of the agents is confined to a specific time of day that is capable of adjusting the prolactin profile of the patient to conform or to approach the standard human prolactin profile.
[0022] Additionally, the supplementation of the prolactin agonists in U.S. Pat. No. 5,605,885 (“the '885 patent”) disclose a method for the stimulation of a suppressed or deficient immune system by regulating the blood levels or activity of the hormone prolactin directly. The '885 patent method comprises treating an immunosuppressed subject with proteins, peptides and compounds that have prolactin-like activity including, but not limited to, prolactin, peptide sequences from prolactin that have prolactin-like activity, growth hormone (a structurally similar and biologically related hormone), or peptide sequences from growth hormone which have prolactin-like activity, placental lactogens, and any genetically engineered protein sequence which has prolactin-like activity. However, neither the '885 and '127 patents provide teachings regarding increasing prolactin levels by the administration of the growth hormone releasing hormone (“GHRH”) as a DNA form.
[0023] In summary, the production of recombinant proteins in the last 2 decades provides a useful tool for the treatment of many diverse conditions, however these treatments have some significant drawbacks. It has also been demonstrated that nucleic acid expression constructs that encode recombinant proteins are viable solutions to the problems of frequent injections and high cost of traditional recombinant therapy. By utilizing knowledge of specific pituitary/hypothalamic pathways and the functionality of extracranially secreted hormones, it is possible to treat many conditions utilizing a plasmid-mediated introduction of a nucleic acid construct into a subject. Furthermore, it has been shown that some beneficial effects can be conferred to the offspring of female subjects that have been treated utilizing recombinant proteins during gestation and without treating the offspring directly. Thus, this invention is related to the conferred beneficial effects in offspring from GHRH treated mothers. More specifically this invention discloses methods for altering pituitary development and pituitary hormone secretion (e.g. prolactin) in the offspring from female subjects treated with nucleic acid constructs that encode GHRH.
SUMMARY
[0024] The present invention pertains to a plasmid-meditated gene supplementation to alter pituitary development, and to increase prolactin levels, in an offspring of a female subject. One embodiment of the present invention pertains to administering to a female subject a nucleic acid expression construct that encodes growth hormone releasing hormone (“GHRH”) to alter the pituitary development and pituitary hormone secretion (e.g. prolactin, “PRL”) in the offspring from the female subject.
[0025] The present plasmid-mediated gene supplementation method results in an increase in the pituitary lactotrophs (pituitary cells that specifically produce prolactin), an increase in the number and production of PRL by the pituitary gland, and an increase in the prolactin levels in an offspring from the female subject.
[0026] The female subject may be a mother, a female who has never been pregnant or given birth before, or a surrogate mother, such as impregnated by fetal transplantation. Although the nucleic acid construct can be in a variety of different configurations, a preferred embodiment of the construct comprises a promoter, a nucleotide sequence, and a 3′ untranslated region. The nucleic acid sequence may comprise a growth hormone releasing hormone (“GHRH”) or a biological equivalent thereof, a myogenic promoter, and a specified 3′ untranslated region. Another embodiment includes the use of modified GHRH analogs that have been engineered to be protease resistant, but retain the functional biological activity of the wild-type GHRH. The delivery of the nucleic acid expression construct into the female subject may be accompanied or assisted. Although electroporation is a preferred method to deliver the nucleic acid expression construct into the cells of the female subject, other approaches can be utilized for this purpose. In a specific embodiment of the current invention, muscle cells are the preferred cell type for delivery of the nucleic acid expression construct, however, other cell types (e.g. somatic cells, stem cells, or germ cells) can be utilized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 shows the nucleic acid constructs that were used in pregnant rats. Thirty micrograms of a pSP-HV-GHRH (SEQ ID#11) nucleic acid construct was delivered into the tibialis anterior muscle of rat dams at 16 days of gestation. Control dams were injected with a similar construct driving the reporter, beta-galactosidase. The injection was followed by in vivo electroporation.
[0028] FIG. 2 shows the increased postnatal growth in offspring from rats treated with the nucleic acid constructs pSP-HV-GHRH (SEQ ID#11) and beta-galactosidase (“β-gal”). Significant weight differences (*) for both sexes were recorded at 3 weeks of age (p<0.05), and at 10 weeks of age (p<0.05). Female offspring from β-gal treated control dams (“CF”); female offspring of pSP-HV-GHRH (SEQ ID#11)-treated dams—(“IF”), male offspring from β-gal treated control dams (“CM”); male offspring of pSP-HV-GHRH (SEQ ID#11)-treated dams—(“IM”),
[0029] FIG. 3 shows muscle hypertrophy in the offspring of the pSP-HV-GHRH (SEQ ID#11) treated dams. Both male and female offspring from pSP-HV-GHRH (SEQ ID#11) treated animals had muscle hypertrophy at 3 weeks of age. Gastrocnemius weight/body weight (“G/wt”); Tibialis anterior weight/body weight (“TA/wt”), wherein the differences were significant at *=p<0.02; #=p<0.008;°=p<0.01. At 24 weeks of age the female offspring of the pSP-HV-GHRH (SEQ ID#11) treated dams maintained their muscle hypertrophy, whereas males were similar to controls. Gastrocnemius weight/total body weight (“G/wt”); and Soleus weight/total body weight (“S/wt”) wherein the differences were significant at §=p<0.007.
[0030] FIG. 4 shows the table and histogram of the fold activation of IGF-I levels in offspring from pSP-HV-GHRH (SEQ ID#11)-treated dams over the fold activation of the offspring from β-gal treated dams at 3, 12, and 24, weeks of age of the offspring. The circulating IGF-I levels were measured by specific rat radioimmunoassay (“RIA”). The histogram depicts fold IGF-I between age and sex matched controls, wherein the values are significant (*) at p<0.05. Female offspring from β-gal treated control dams (“CF”); female offspring of sp-HV-GHRH-treated dams—(“IF”), male offspring from β-gal treated control dams (“CM”); male offspring of sp-HV-GHRH-treated dams—(“IM”). Rat IGF-I was measured by specific radioimmunoassay (Diagnostic System Laboratories, Webster, Tex.). The sensitivity of the assay was 0.8 ng/ml; intra-assay and inter-assay coefficients of variation were 2.4% and 4.1%, respectively.
[0031] FIG. 5 shows that both male and female offspring from pSP-HV-GHRH (SEQ ID#11) treated dams had pituitary hypertrophy at 3 and 12 weeks, as measured by the pituitary weight/total body weight ratio.
[0032] FIG. 6 shows a Northern blot analysis of pituitary tissue from male offspring (“c3W”) from β-gal treated control dams and male (“IM3W”) and female (“IF3W”) offspring from pSP-HV-GHRH (SEQ ID#11) treated dams at 3 weeks. RNA was visualized using probes for the 18s rRNA (“18S”) loading marker; a rat growth hormone releasing hormone specific cDNA probe (“GHRH”); a growth hormone specific rat (“GH”) cDNA probe; and a rat prolactin specific cDNA probe. The intensity of the bands was determined using a Phosphoimager (Molecular Dynamics) and associated software. Histogram (B) shows fold increase in GH and PRL levels of the offspring from the pSP-HV-GHRH (SEQ ID#11) treated dams over the GH and PRL levels of the offspring from β-gal treated control dams. Pituitaries that had been snap frozen were homogenized in—I will have to add the composition, and extracted. Total RNA was DNase I treated and 20 μg of RNA, DNA free was size separated in 1.5% agarose-formaldehyde gel and transferred to nylon membrane. The membranes were hybridized with specific GHRH, GH (gift from Dr. Kelly Mayo at Northwestern University, Chicago, Ill.) and PRL cDNA riboprobes 32 P-labeled (gift from Dr. Kathleen Mahon at Baylor College of Medicine, Houston, Tex.).
[0033] FIG. 7 shows immunostained sections of pituitary glands from the 3 week old offspring of pSP-HV-GHRH (SEQ ID#11) and β-gal treated dams. Panel A depicts rat GH-specific staining and Panel B depicts rat prolactin-specific staining, wherein the anterior pituitary from offspring of β-gal treated control dams (“CP”); anterior pituitary from offspring of pSP-HV-GHRH (SEQ ID#11) treated dams (“TP”); and the anterior pituitary from offspring of pSP-HV-GHRH (SEQ ID#11) treated dams with the immunostaining wherein no primary antibody was added to the incubation reaction (“NC”), are shown.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Terms:
[0034] It will be readily apparent to one skilled in the art that various substitutions and modifications may be made in the invention disclosed herein without departing from the scope and spirit of the invention.
[0035] The term “a” or “an” as used herein in the specification may mean one or more. As used herein in the claim(s), when used in conjunction with the word “comprising”, the words “a” or “an” may mean one or more than one. As used herein “another” may mean at least a second or more.
[0036] The term “animal” as used herein refers to any species of the animal kingdom. In preferred embodiments it refers more specifically to humans, animals in their wild state, animals used as pets (birds, dogs, cats, horses), animals used for work (horses, cows, dogs) and animals which produce food (chickens, cows, fish), farm animals (pigs, horses, cows, sheep, chickens) or are themselves food (frogs, chickens, fish, crabs, lobsters, shrimp, mussels, scallops, goats, boars, cows, lambs, pigs, ostrich, emu, eel) and other animals well known to the art.
[0037] The term “effective amount” as used herein is defined as the amount of the composition required to produce an effect in a host which can be monitored using several endpoints known to those skilled in the art. In a specific embodiment, these endpoints are surrogate markers.
[0038] The term “feed conversion efficiency” as used herein is defined as the amount of food an animal eats per day versus the amount of weight gained by said animal. The terms “efficiency” or “feed efficiency” as used herein is interchangeable with “feed conversion efficiency.”
[0039] The term “growth deficiencies” as used herein is defined as any health status, medical condition or disease in which growth is less than normal. The deficiency could be the result of an aberration directly affecting a growth hormone pathway (such as the GHRH-GH-IGF-I axis), indirectly affecting a growth hormone pathway, or not affecting a growth hormone pathway at all.
[0040] The term “growth hormone” as used herein is defined as a hormone which relates to growth and acts as a chemical messenger to exert its action on a target cell.
[0041] The term “growth hormone releasing hormone” as used herein is defined as a hormone which facilitates or stimulates release of growth hormone.
[0042] The term “growth hormone releasing hormone analog” as used herein is defined as protein which contains amino acid mutations and/or deletions in the naturally occurring form of the amino acid sequence (with no synthetic dextro or cyclic amino acids), but not naturally occurring in the GHRH molecule, yet still retains its function to enhance synthesis and secretion of growth hormone.
[0043] The term “growth hormone secretagogue receptor” (GHS-R) as used herein is defined as a receptor for a small synthetic compound which is associated, either directly or indirectly, with release of growth hormone from the pituitary gland.
[0044] The term “ligand for a growth hormone secretagogue receptor” as used herein is defined as any compound which acts as an agonist on a growth hormone secretagogue receptor. The ligand may be synthetic or naturally occurring. The ligand may be a peptide, protein, sugar, carbohydrate, lipid, nucleic acid or a combination thereof.
[0045] The term “myogenic” as used herein refers specifically to muscle tissue.
[0046] The term “newborn” as used herein refers to an animal immediately after birth and all subsequent stages of maturity or growth.
[0047] The term “offspring” as used herein refers to a progeny of a parent, wherein the progeny is an unborn fetus or a newborn.
[0048] The term “parenteral” as used herein refers to a mechanism for introduction of material into an animal other than through the intestinal canal. In specific embodiments, parenteral includes subcutaneous, intramuscular, intravenous, intrathecal, intraperitoneal, or
[0049] The term “pharmaceutically acceptable” as used herein refers to a compound wherein administration of said compound can be tolerated by a recipient mammal.
[0050] The term “secretagogue” as used herein refers to a natural synthetic molecule that enhances synthesis and secretion of a downstream-regulated molecule (e.g. GHRH is a secretagogue for GH).
[0051] The term “somatotroph” as used herein refers to a cell which produces growth hormone.
[0052] The term “lactotroph” as used herein refers to a cell which produces prolactin.
[0053] The term “therapeutically effective amount” as used herein refers to the amount of a compound administered wherein said amount is physiologically significant. An agent is physiologically significant if its presence results in technical change in the physiology of a recipient animal. For example, in the treatment of growth deficiencies, a composition which increases growth would be therapeutically effective; in consumption diseases a composition which would decrease the rate of loss or increase the growth would be therapeutically effective.
[0054] The term “vector” as used herein refers to any vehicle which delivers a nucleic acid into a cell or organism. Examples include plasmids, viral vectors, liposomes, or cationic lipids. In a specific embodiment, liposomes and cationic lipids are adjuvant (carriers) that can be complexed with other vectors to increase the uptake of plasmid or viral vectors by a target cell. In a preferred embodiment, the vector comprises a promoter, a nucleotide sequence, preferably encoding a growth hormone releasing hormone, its biological equivalent, or its analog, and a 3′ untranslated region. In another preferred embodiment, the promoter, nucleotide sequence, and 3′ untranslated region are linked operably for expression in a eukaryotic cell.
[0055] The term “nucleic acid expression construct” as used herein refers to any type of genetic construct comprising a nucleic acid coding for a RNA capable of being transcribed. The term “expression vector” can also be used interchangeably.
[0056] The term “functional biological equivalent” of GHRH as used herein is a polypeptide that has been engineered to contain a distinct amino acid sequence while simultaneously having similar or improved biologically activity when compared to the GHRH polypeptide.
[0057] The term “functional nucleic acid equivalent” of a referenced nucleic acid sequence as used herein means a nucleic acid sequences that has been engineered to contain a distinct nucleic acid sequences while simultaneously having similar or improved functional activity when compared to the referenced nucleic acid sequence. For example, because the universal code is redundant, different codon sequences can express the same amino acid (e.g. ACC, ACA and ACG all code for threonine). Thus, a codon in an expression construct can be changed or optimized, but still codes for an identical amino acid. Similarly, entire functional nucleic acid sequences in an expression vector can be added or deleted without changing the overall functionality of the expression vector. For example, antibiotic resistant genes that are used as selection markers for expression construct replication in bacteria can be added, deleted, or interchanged without altering the in vivo expression functionality the construct.
[0058] The term “subject” as used herein refers to any species of the animal kingdom. In preferred embodiments it refers more specifically to humans and animals used for: pets (e.g. cats, dogs, etc.); work (e.g. horses, cows, etc.); food (chicken, fish, lambs, pigs, etc); and all others known in the art.
[0059] The term “promoter” as used herein refers to a sequence of DNA that directs the transcription of a gene. A promoter may be “inducible”, initiating transcription in response to an inducing agent or, in contrast, a promoter may be “constitutive”, whereby an inducing agent does not regulate the rate of transcription. A promoter may be regulated in a tissue-specific or tissue-preferred manner, such that it is only active in transcribing the operable linked coding region in a specific tissue type or types.
[0060] The term “coding region” as used herein refers to any portion of the DNA sequence that is transcribed into messenger RNA (mRNA) and then translated into a sequence of amino acids characteristic of a specific polypeptide.
[0061] The term “analog” as used herein includes any mutant of GHRH, or synthetic or naturally occurring peptide fragments of GHRH, such as HV-GHRH (SEQ ID#1), TI-GHRH (SEQ ID#2), TV-GHRH (SEQ ID#3), 15/27/28-GHRH (SEQ ID#4), (1-44)NH 2 (SEQ ID#5) or (1-40)OH (SEQ ID#6) forms, or any shorter form to no less than (1-29) amino acids.
[0062] The term “delivery” as used herein is defined as a means of introducing a material into a subject, a cell or any recipient, by means of chemical or biological process, injection, mixing, electroporation, sonoporation, or combination thereof, either under or without pressure.
[0063] The term “growth hormone” (“GH”) as used herein is defined as a hormone that relates to growth and acts as a chemical messenger to exert its action on a target cell.
[0064] The term “growth hormone releasing hormone” (“GHRH”) as used herein is defined as a hormone that facilitates or stimulates release of growth hormone, and in a lesser extent other pituitary hormones, as prolactin.
[0065] The term “regulator protein” as used herein refers protein that increasing the rate of transcription in response to an inducing agent.
[0066] The term “modified cells” as used herein is defined as the cells from a subject that have an additional nucleic acid sequence introduced into the cell.
[0067] The term “lean body mass” (“LBM”) as used herein is defined as the mass of the body of an animal attributed to non-fat tissue such as muscle.
[0068] The term “cassette” as used herein is defined as one or more transgene expression vectors.
[0069] The term “post-injection” as used herein refers to a time period following the introduction of a nucleic acid cassette that contains heterologous nucleic acid sequence encoding GHRH or biological equivalent thereof into the cells of the subject and allowing expression of the encoded gene to occur while the modified cells are within the living organism.
[0070] The term “heterologous nucleic acid sequence” as used herein is defined as a DNA sequence consisting of differing regulatory and expression elements.
[0071] The term “regulator protein” as used herein refers to any protein that can be used to control the expression of a gene.
[0072] The term “electroporation” as used herein refers to a method that utilized electric pulses to deliver a nucleic acid sequence into cells.
[0073] The term “poly-L-glutamate (“PLG”)” as used herein refers to a biodegradable polymer of L-glutamic acid that is suitable for use as a vector or adjuvant for DNA transfer into cells with or without electroporation.
[0074] In an embodiment of the present invention, a nucleic acid expression construct is utilized in a plasmid meditated gene supplementation method. The consequence of the claimed supplementation method results in change in the pituitary lineage, with increased number of lactotrophs and an increase in the prolactin levels in an offspring from a female subject. The female subject may be a mother, a female who has never been pregnant or given birth before, or a surrogate mother, such as impregnated by fetal transplantation. Modification of the pituitary gland lineage in the female subject's offspring is achieved by utilizing a nucleic acid expression construct that is delivered into the cells of a female subject prior to or during gestation of the offspring. Although the nucleic acid constructs comprise a variety of different configurations, a preferred embodiment describes the construct comprising a promoter, a nucleotide sequence, and a 3′ untranslated region. The nucleic acid sequence may comprise a growth hormone releasing hormone (“GHRH”) or biological equivalent thereof, with a myogenic promoter, and a specified 3′ untranslated region. Further embodiments also include the use of modified nucleic acid sequences that encode GHRH analogs that have been engineered to be protease resistant, but retain the functional biological activity of the wild-type GHRH.
[0075] Following the delivery of the nucleic acid expression construct into the female subject, the process of electroporation can be utilized to facilitate the uptake of the construct into the cells of the female subject. Although electroporation is a preferred method to deliver the nucleic acid expression construct into the cells of the female subject, other approaches can be utilized for this purpose, and are disclosed herein. In a specific embodiment of the current invention, muscle cells are the preferred cell type for delivery of the nucleic acid expression construct, however, other cell types (e.g. somatic cells, stem cells, or germ cells) can be utilized.
[0076] In order to assess growth effects of the growth hormone releasing hormone (“GHRH”) utilizing plasmid meditated gene supplementation, several experiments that utilized myogenic vectors with an encoded GHRH gene were conducted. The outcome resulted in a co-pending patent application (i.e. U.S. patent application Ser. No. 10/021,403 filed on Dec. 12, 2001, and is hereby incorporated by reference) that disclosed methods used to treat pregnant sows in the last trimester of gestation with a vector containing a nucleic acid sequences for GHRH or biological equivalents thereof. Injection of the nucleic acid expression construct was followed by electroporation. Non-injected/electroporated sows were used as controls. The piglets from the GHRH injected sow were found to be bigger at birth. Cross-fostering studies were then performed, and at weaning, the piglets from injected sows remained bigger than controls. Cross-foster controls suckled on injected sows were also significantly bigger than their littermates. Multiple biochemical measurements were performed on the piglets and indicated that piglets born to sows treated with plasmid meditated gene supplementation of GHRH showed an increase in growth pattern over normal levels. Although not wanting to be bound by theory, this proof of principal experiment demonstrated that plasmid meditated gene supplementation could be useful to enhance certain animal characteristics throughout generations, while avoiding secondary effects linked with classical supplementation treatments.
[0077] Although not wanting to be bound by theory, pituitary gland development, including regulation and differentiation of somatotrophs depends upon paracrine processes within the pituitary itself and involves several growth factors and neuropeptides, such as vasoactive intestinal peptide, angiotensin, endothelin, and activin. Secretion of growth hormone (“GH”) is stimulated by a natural GH secretagogue called growth hormone releasing hormone (“GHRH”), and inhibited by somatostatin (“SS”), which are both hypothalamic hormones. In healthy adult mammals, GH is released in a highly regulated, distinctive pulsatile pattern, which occurs when the stimulatory properties of GHRH are enabled by the diminution or withdrawal of SS secretion. The episodic pattern of GH secretion has profound importance for its biological activity and is required for the induction of its physiological effects at the peripheral level. Regulated GH secretion is essential for optimal linear growth, homeostasis of carbohydrate, protein, and fat metabolism, and for promoting a positive nitrogen balance (Murray, et al., 2000). These effects are mediated largely by its down-stream effector, insulin-like growth factor I (“IGF-I”). GH secretion also is influenced in vivo by ghrelin, the newly identified endogenous peptide ligand of the growth hormone secretagogue receptor, and is dependent on GHRH (Hataya, et al., 2001) for its GH-secretory activity (Horvath, et. al., 2001). In this invention, we disclose a method to alter pituitary gland development in the offspring of female subjects that were treated with plasmid mediated gene supplementation of GHRH. This method allows the pregnant subjects to be treated during the last trimester of gestation and alter the lineage specification of the pituitary gland as well as expression levels of growth hormone (“GH”) and prolactin somatotrophs, without directly treating the offspring.
[0078] Hypothalamic tissue-specific expression of the GHRH gene is not required for its biological activity, as indicated by the biological activity of extra-cranially secreted GHRH (Faglia, et. al., 1992; Melmed, et. al., 1991). Recently, we showed that in pigs, ectopic expression of a novel, serum protease-resistant porcine GHRH driven by a synthetic muscle-specific promoter could elicit robust GH and IGF-I responses following its in vivo administration by intramuscular injection and electroporation (Lopez-Calderon, et al., 1999). In the rat model, GHRH administration is effective in inducing pituitary GH mRNA expression and increasing GH content, as well as somatic growth, with the endogenous episodic GHRH secretory pattern present in males enhancing somatic growth over females (Borski, et. al., 2000). Although, the intergenerational effects on the offspring of pregnant animals with sustained GHRH expression are yet unknown, studies in adult animals indicate a potential plasticity of the GH somatotrophs in response to GHRH. Pathological GHRH stimulation (irrespective of its source, from transgenic models to pancreatic tumors) of GH secretion can result in proliferation, hyperplasia, and adenomas of the adenohypophysial cells (Asa, et. al., 1992; Sano, et. al., 1988). A preferred embodiment of the present invention utilizes the growth hormone-releasing hormone analog having a similar amino acid sequence of the wild-type (“wt”) plasmid. As used herein, the term wt or “wild-type” can be the endogenous form of GHRH of any animal, or it may be a slightly modified form of the hormone, such as the porcine GHRH. A skilled artisan is aware that the endogenous GHRH has 44 amino acids, and an amide group at the end, with the correct notation for that form being (1-44)NH 2 -GHRH. In a specific embodiment, a form with only 40 amino acids (lacking the last 4 amino acids) is used which also does not contain an amide group, and may be referred to as (1-40)OH-GHRH. This form as used herein may also be referred to as wild-type because it does not contain internal mutations if compared to the wild-type sequence, as opposed to other forms discussed herein (such as the HV-GHRH discussed below) having internal mutations introduced by site-directed mutagenesis. A skilled artisan is aware that the 1-40 form and shorter forms (for example, 1-32 or 1-29) exist naturally in humans and other mammals (even in different types of GHRH secreting tumors), and they have an activity comparable with the natural (1-44)NH 2 . In a preferred embodiments of the present invention GHRH equivalents with increased stability over wild type GHRH peptides are utilized.
[0079] In other embodiments, different species of GHRH or an analog of GHRH are within the scope of the invention. In an object of the invention the residues encoded by the DNA are not modified post-translationally, given the nature of the nucleic acid administration.
[0080] The following species are within the scope of the present invention. U.S. Pat. No. 4,223,019 discloses pentapeptides having the amino acid sequence NH 2 —Y-Z-E-G-J-COOH, wherein Y is selected from a group consisting of D-lysine and D-arginine; Z and J are independently selected from a group consisting of tyrosine, tryptophan, and phenylalanine; and E and G are independently selected from a group consisting of D-tyrosine, D-tryptophan, and D-phenylalanine. U.S. Pat. No. 4,223,020 discloses tetrapeptides having the following amino acid sequence NH 2 -Y-Z-E-G-COOH wherein Y and G are independently selected from a group consisting of tyrosine, tryptophan, and phenylalanine; and Z and E are independently selected from a group consisting of D-tyrosine, D-tryptophan, and D-phenylalanine. U.S. Pat. No. 4,223,021 discloses pentapeptides having the following amino acid sequence NH 2 -Y-Z-E-G-J-COOH wherein Y and G are independently selected from a group consisting of tyrosine, tryptophan, and phenylalanine; Z is selected from a group consisting of glycine, alanine, valine, leucine, isoleucine, proline, hydroxyproline, serine, threonine, cysteine, and methionine; and E and J are independently selected from a group consisting of D-tyrosine, D-tryptophan, and D-phenylalanine. U.S. Pat. No. 4,224,316 discloses novel pentapeptides having the following amino acid sequence NH 2 -Y-Z-E-G-J-COOH wherein Y and E are independently selected from a group consisting of D-tyrosine, D-tryptophan, and D-phenylalanine; Z and G are independently selected from a group consisting of tyrosine, tryptophan, and phenylalanine; and J is selected from a group consisting of glycine, alanine, valine, leucine, isoleucine, proline, hydroxyproline, serine, threonine, cysteine, methionine, aspartic acid, glutamic acid, asparagine, glutamine, arginine, and lysine. U.S. Pat. No. 4,226,857 discloses pentapeptides having the following amino acid sequence NH 2 -Y-Z-E-G-J-COOH wherein Y and G are independently selected from a group consisting of tyrosine, trytophan, and phenylalanine; Z and J are independently selected from a group consisting of D-tyrosine, D-tryptophan, and D-phenylalanine; and E is selected from a group consisting of glycine, alanine, valine, leucine, isoleucine, proline, hydroxyproline, serine, threonine, cysteine, methionine, aspartic acid, glutamic acid, asparagine, glutamine, and histidine. U.S. Pat. No. 4,228,155 discloses pentapeptides having the following amino acid sequence NH 2 -Y-Z-E-G-J-COOH wherein Y is selected from a group consisting of tyrosine, D-tyrosine, tryptophan, D-tryptophan, phenylalanine, and D-phenylalanine; Z and E are independently selected from a group consisting of D-tyrosine, D-tryptophan, and D-phenylalanine; G is selected from a group consisting of lysine and arginine; and J is selected from a group consisting of glycine, alanine, valine, leucine, isoleucine, proline, hydroxyproline, serine, threonine, cysteine, and methionine. U.S. Pat. No. 4,228,156 discloses tripeptides having the following amino acid sequence NH 2 -Y-Z-E-COOH wherein Y and Z are independently selected from a group consisting of D-tyrosine, D-tryptophan, and D-phenylalanine; and E is selected from a group consisting of tyrosine, tryptophan, and phenylalanine. U.S. Pat. No. 4,228,158 discloses pentapeptides having the following amino acid sequence NH 2 -Y-Z-E-G-J-COOH wherein Y and G are independently selected from a group consisting of tyrosine, tryptophan, and phenylalanine, Z and E are independently selected from a group consisting of D-tyrosine, D-tryptophan, and D-phenylalanine; and J is selected from a group consisting of natural amino acids and the D-configuration thereof. U.S. Pat. No. 4,833,166 discloses a synthetic peptide having the formula: H-Asp-Pro-Val-Asn-Ile-Arg-Ala-Phe-Asp-Asp-Val-Leu-Y wherein Y is OH or NH 2 or a non-toxic salt thereof and A synthetic peptide having the formula: H-Val-Glu-Pro-Gly-Ser-Leu-Phe-Leu-Val-Pro-Leu-Pro-Leu-Leu-Pro-Val-His-Asp-Phe-Val-Gln-Gln-Phe-Ala-Gly-Ile-Y wherein Y is OH or NH 2 or a non-toxic salt thereof. Draghia-Akli, et al. (1997) utilize a 228-bp fragment of hGHRH which encodes a 31-amino-acid signal peptide and an entire mature peptide human GHRH(1-44)OH (Tyr1 Leu44).
[0081] The embodiments of the present invention include: (1) a method for changing the pituitary gland lineage, with an increased number of somatotrophs and lactotrophs in an offspring; and (2) a method for stimulating production of prolactin in an offspring at a level greater than that associated with normal growth. All of these methods include the step of introducing a nucleic acid construct or plasmid vector into the mother of the offspring during gestation of the offspring or during a previous pregnancy, wherein said vector comprises a promoter; a nucleotide sequence, such as one encoding a growth hormone releasing hormone or biological equivalent thereof; and a 3′ untranslated region operatively linked sequentially at appropriate distances for functional expression.
[0082] It is an object of the present invention to change the pituitary lineage, and increase levels of prolactin in an animal, preferably an offspring from a mother. The preferred embodiments allow modifications in the pituitary lineage, and increase levels of prolactin in an animal for long terms, such as greater than a few weeks or greater than a few months. In a specific embodiment, this is achieved by administering growth hormone releasing hormone into the mother of the offspring, preferably in a nucleic acid form. In a preferred embodiment the GHRH nucleic acid is maintained as an episome in a muscle cell. In a specific embodiment the increase in GHRH affects the pituitary gland by increasing the number of growth hormone producing cells, and consequently changes their cellular lineage. Although not wanting to be bound by theory, the ratio of somatotrophs (growth hormone producing cells) is increased relative to other hormone producing cells in the pituitary, such as corticotrophs, lactotrophs, gonadotrophs, etc. Thus, the increase in growth hormone may be related to the rise in the number of growth hormone-producing cells. Likewise, increases in pituitary hormones, such as prolactin, may be related to the rise in the number of prolactin producing cells in the pituitary.
[0083] Prolactin is a single-chain protein hormone and is closely related to growth hormone. It is chiefly secreted by lactotrophs in the anterior pituitary. However, prolactin is also synthesized and secreted by a broad range of other cells in the body, most prominently various immune cells, the brain and the decidua of the pregnant uterus. Prolactin is also found in the serum of normal females and males. Prolactin secretion is pulsatile and also shows diurnal variation, with the serum concentration increasing during sleep and the lowest level occurs about 3 hours after waking. The secretion of prolactin is increased by stress and appears to be dependent upon a women's estrogen status.
[0084] The conventional view of prolactin is that the mammary gland is its major target organ, and stimulating mammary gland development along with milk production define its major functions. Although these views are true, such descriptions fail to convey an accurate depiction of this multifunctional hormone. For example, it is difficult to find a mammalian tissue that does not express prolactin receptors, and although the anterior pituitary is the major source of prolactin, the hormone is synthesized and secreted in many other tissues. Overall, several hundred different actions have been reported for prolactin in various species. Some of prolactin's major effects are summarized below.
[0085] Prolactin's major known functions are attributed with mammary gland development, milk production and reproduction. In the 1920's it was found that extracts of the pituitary gland, when injected into virgin rabbits, induced milk production. Subsequent research demonstrated that prolactin has two major roles in milk production: induction of lobuloalveolar growth of the mammary gland; and stimulation of lactogenesis after birth. Prolactin, along with cortisol and insulin, act together to stimulate transcription of the genes that encode milk proteins. Prolactin is also important in several non-lactational aspects of reproduction. For example, in some species (e.g. rodents, dogs, skunks), prolactin is necessary for maintenance of ovarian structures (i.e. corpora lutea) that secrete progesterone. Mice that are homozygous for an inactivated prolactin gene and thus incapable of secreting prolactin are infertile due to defects in ovulation, fertilization, preimplantation development and implantation. Prolactin also appears to have stimulatory effects in some species on reproductive or maternal behaviors such as nest building and retrieval of scattered young.
[0086] Prolactin also appears to elicit effects in the immune system. For example, the prolactin receptor is widely expressed by immune cells, and some types of lymphocytes synthesize and secrete prolactin. These observations suggest that prolactin may act as an autocrine or paracrine modulator of immune activity. Conversely, mice with homozygous deletions of the prolactin gene fail to show significant abnormalities in immune responses. A considerable amount of research is in progress to delineate the role of prolactin in normal and pathologic immune responses. Although the significance of these potential functions remains poorly understood, it is clear that prolactin can stimulate and enhance the immune system, which has been demonstrated in prior art (e.g. U.S. Pat. Nos. 5,605,885; and 5,872,127). Furthermore, the present invention indicates how increased prolactin levels are correlated with increased IGF-I levels.
[0087] In a preferred embodiment the promoter is a synthetic myogenic promoter and hGH 3′ untranslated region (SEQ ID#8) is in the 3′ untranslated region. However, the 3 untranslated region may be from any natural or synthetic gene. In a specific embodiment of the present invention there is utilized a synthetic promoter, termed SPc5-12 (SEQ ID#7) (Li, et al., 1999), which contains proximal serum response elements (“SRE”) from skeletal α-actin, multiple MEF-2 sites, MEF-1 sites, and TEF-1 binding sites, and greatly exceeds the transcriptional potencies of natural myogenic promoters. In a preferred embodiment the promoter utilized in the invention does not get shut off or reduced in activity significantly by endogenous cellular machinery or factors. Other elements, including trans-acting factor binding sites and enhancers may be used in accordance with this embodiment of the invention. In an alternative embodiment, a natural myogenic promoter is utilized, and a skilled artisan is aware how to obtain such promoter sequences from databases including the National Center for Biotechnology Information (NCBI) GenBank database or the NCBI PubMed site. A skilled artisan is aware that these World Wide Web sites may be utilized to obtain sequences or relevant literature related to the present invention.
[0088] In a specific embodiment the human growth hormone (“hGH”) hgH 3′ (SEQ ID#8) untranslated region or polyadenylation signal is utilized in a nucleic acid construct, such as a plasmid.
[0089] In specific embodiments the nucleic acid construct is selected from the group consisting of a plasmid, a viral vector, a liposome, or a cationic lipid. In further specific embodiments said vector is introduced into myogenic cells or muscle tissue. In a further specific embodiment said animal is a human, a pet animal, a work animal, or a food animal.
[0090] In addition to the specific embodiment of introducing the nucleic acid construct into the animal via a plasmid vector, delivery systems for transfection of nucleic acids into the animal or its cells known in the art may also be utilized. For example, other non-viral or viral methods may be utilized. A skilled artisan recognizes that a targeted system for non-viral forms of DNA or RNA requires four components: 1) the DNA or RNA of interest; 2) a moiety that recognizes and binds to a cell surface receptor or antigen; 3) a DNA binding moiety; and 4) a lytic moiety that enables the transport of the complex from the cell surface to the cytoplasm. Further, liposomes and cationic lipids can be used to deliver the therapeutic gene combinations to achieve the same effect. Potential viral vectors include expression vectors derived from viruses such as adenovirus, retrovirus, vaccinia virus, herpes virus, and bovine papilloma virus. In addition, episomal vectors may be employed. Other DNA vectors and transporter systems are known in the art.
[0091] Vectors. One skilled in the art recognizes that expression vectors derived from various bacterial plasmids, retroviruses, adenovirus, herpes or from vaccinia viruses may be used for delivery of nucleotide sequences to a targeted organ, tissue or cell population. Methods which are well known to those skilled in the art can be used to construct recombinant vectors that will express the gene encoding the growth hormone releasing hormone analog. Transient expression may last for a month or more with a non-replicating vector and even longer if appropriate replication elements are a part of the vector system, wherein the term “vector” is used to refer to a carrier nucleic acid molecule into which a nucleic acid sequence can be inserted for introduction into a cell where the vector can be replicated and the nucleic acid sequence can be expressed. The term vector can also be referred to as a nucleic acid construct. A nucleic acid sequence can be “exogenous,” which means that it is foreign to the cell into which the vector is being introduced or that the sequence is homologous to a sequence in the cell but in a position within the host cell nucleic acid in which the sequence is ordinarily not found. Vectors include plasmids, cosmids, viruses (bacteriophage, animal viruses, and plant viruses), and artificial chromosomes (e.g., YACs). One of skill in the art would be well equipped to construct a vector through standard recombinant techniques, which are described in Maniatis et al., 1988 and Ausubel et al., 1994, both incorporated herein by reference.
[0092] The term “expression vector” refers to a vector or nucleic acid expression construct containing a nucleic acid sequence coding for at least part of a gene product capable of being transcribed. In a specific embodiment the nucleic acid sequence encodes part or all of GHRH. In some cases, RNA molecules are then translated into a protein, polypeptide, or peptide. In other cases, these sequences are not translated, for example, in the production of antisense molecules or ribozymes. Expression vectors can contain a variety of “control sequences,” which refer to nucleic acid sequences necessary for the transcription and possibly translation of an operably linked coding sequence in a particular host organism. In addition to control sequences that govern transcription and translation, vectors and expression vectors may contain nucleic acid sequences that serve other functions as well and are described infra.
[0093] In a preferred embodiment, the nucleic acid construction construct or vector of the present invention is a plasmid which comprises a synthetic myogenic (muscle-specific) promoter, a nucleotide sequence encoding a growth hormone releasing hormone or its analog, and a 3′ untranslated region. In alternative embodiments, the vectors is a viral vector, such as an adeno-associated virus, an adenovirus, or a retrovirus. In alternative embodiments, skeletal alpha-actin promoter, myosin light chain promoter, cytomegalovirus promoter, or SV40 promoter can be used. In other alternative embodiments, human growth hormone, bovine growth hormone, SV40, or skeletal alpha actin 3′ untranslated regions are utilized in the vector.
[0094] Promoters and Enhancers. A “promoter” is a control sequence that is a region of a nucleic acid sequence at which initiation and rate of transcription are controlled. It may contain genetic elements at which regulatory proteins and molecules may bind such as RNA polymerase and other transcription factors. The phrases “operatively positioned,” “operatively linked,” “under control,” and “under transcriptional control” mean that a promoter is in a correct functional location and/or orientation in relation to a nucleic acid sequence to control transcriptional initiation and/or expression of that sequence. A promoter may or may not be used in conjunction with an “enhancer,” which refers to a cis-acting regulatory sequence involved in the transcriptional activation of a nucleic acid sequence.
[0095] A promoter may be one of naturally-coding sequences located upstream of the coding segment and/or exon. Such a promoter can be referred to as “endogenous.” Similarly, an enhancer may be one naturally associated with a nucleic acid sequence, located either downstream or upstream of that sequence. Alternatively, certain advantages will be gained by positioning the coding nucleic acid segment under the control of a recombinant or heterologous promoter, which refers to a promoter that is not normally associated with a nucleic acid sequence in its natural environment. A recombinant or heterologous enhancer refers also to an enhancer not normally associated with a nucleic acid sequence in its natural environment. Such promoters or enhancers may include promoters or enhancers of other genes, and promoters or enhancers isolated from any other prokaryotic, viral, or eukaryotic cell, and promoters or enhancers not “naturally occurring,” i.e., containing different elements of different transcriptional regulatory regions, and/or mutations that alter expression. In addition to producing nucleic acid sequences of promoters and enhancers synthetically, sequences may be produced using recombinant cloning and/or nucleic acid amplification technology, including PCR™. Furthermore, it is contemplated the control sequences that direct transcription and/or expression of sequences within non-nuclear organelles such as mitochondria, chloroplasts, and the like, can be employed as well.
[0096] Naturally, it will be important to employ a promoter and/or enhancer that effectively directs the expression of the DNA segment in the cell type, organelle, and organism chosen for expression. Those of skill in the art of molecular biology generally know the use of promoters, enhancers, and cell type combinations for protein expression. The promoters employed may be constitutive, tissue-specific, inducible, and/or useful under the appropriate conditions to direct high level expression of the introduced DNA segment, such as is advantageous in the large-scale production of recombinant proteins and/or peptides. The promoter may be heterologous or endogenous. In a specific embodiment the promoter is a synthetic myogenic promoter, such as is described in Li, et al. (1999).
[0097] The identity of tissue-specific promoters or elements, as well as assays to characterize their activity, is well known to those of skill in the art. Examples of such regions include the human LIMK2 gene, the somatostatin receptor 2 gene, murine epididymal retinoic acid-binding gene, human CD4, mouse alpha2 (XI) collagen, D1A dopamine receptor gene, insulin-like growth factor II, human platelet endothelial cell adhesion molecule-1.
[0098] Initiation Signals and Internal Ribosome Binding Sites. A specific initiation signal also may be required for efficient translation of coding sequences. These signals include the ATG initiation codon or adjacent sequences. Exogenous translational control signals, including the ATG initiation codon, may need to be provided. One of ordinary skill in the art would readily be capable of determining this and providing the necessary signals. It is well known that the initiation codon must be “in-frame” with the reading frame of the desired coding sequence to ensure translation of the entire insert. The exogenous translational control signals and initiation codons can be either natural or synthetic. The efficiency of expression may be enhanced by the inclusion of appropriate transcription enhancer elements.
[0099] In certain embodiments of the invention, the use of internal ribosome entry sites (IRES) elements are used to create multigene, or polycistronic, messages. IRES elements are able to bypass the ribosome scanning model of 5′ methylated Cap dependent translation and begin translation at internal sites. IRES elements from two members of the picornavirus family (polio and encephalomyocarditis) have been described, as well an IRES from a mammalian message. IRES elements can be linked to heterologous open reading frames. Multiple open reading frames can be transcribed together, each separated by an IRES, creating polycistronic messages. By virtue of the IRES element, each open reading frame is accessible to ribosomes for efficient translation. Multiple genes can be efficiently expressed using a single promoter/enhancer to transcribe a single message.
[0100] Multiple Cloning Sites. Vectors can include a multiple cloning site (MCS), which is a nucleic acid region that contains multiple restriction enzyme sites, any of which can be used in conjunction with standard recombinant technology to digest the vector. “Restriction enzyme digestion” refers to catalytic cleavage of a nucleic acid molecule with an enzyme that functions only at specific locations in a nucleic acid molecule. Many of these restriction enzymes are commercially available. Use of such enzymes is widely understood by those of skill in the art. Frequently, a vector is linearized or fragmented using a restriction enzyme that cuts within the MCS to enable exogenous sequences to be ligated to the vector. “Ligation” refers to the process of forming phosphodiester bonds between two nucleic acid fragments, which may or may not be contiguous with each other. Techniques involving restriction enzymes and ligation reactions are well known to those of skill in the art of recombinant technology.
[0101] Splicing Sites. Most transcribed eukaryotic RNA molecules will undergo RNA splicing to remove introns from the primary transcripts. Vectors containing genomic eukaryotic sequences may require donor and/or acceptor splicing sites to ensure proper processing of the transcript for protein expression.
[0102] Polyadenylation Signals. In expression, one will typically include a polyadenylation signal to effect proper polyadenylation of the transcript. The nature of the polyadenylation signal is not believed to be crucial to the successful practice of the invention, and/or any such sequence may be employed. Preferred embodiments include the SV40 polyadenylation signal and/or the bovine or human growth hormone polyadenylation signal, convenient and/or known to function well in various target cells. Also contemplated as an element of the expression cassette is a transcriptional termination site. These elements can serve to enhance message levels and/or to minimize read through from the cassette into other sequences.
[0103] Origins of Replication. In order to propagate a vector in a host cell, it may contain one or more origins of replication sites (often termed “ori”), which is a specific nucleic acid sequence at which replication is initiated. Alternatively an autonomously replicating sequence (ARS) can be employed if the host cell is yeast.
[0104] Selectable and Screenable Markers. In certain embodiments of the invention, the cells contain nucleic acid construct of the present invention, a cell may be identified in vitro or in vivo by including a marker in the expression vector. Such markers would confer an identifiable change to the cell permitting easy identification of cells containing the expression vector. Generally, a selectable marker is one that confers a property that allows for selection. A positive selectable marker is one in which the presence of the marker allows for its selection, while a negative selectable marker is one in which its presence prevents its selection. An example of a positive selectable marker is a drug resistance marker, such as the antibiotic resistance gene on the plasmid constructs (such as ampicylin, gentamicin, tetracycline or chloramphenicol).
[0105] Usually the inclusion of a drug selection marker aids in the cloning and identification of transformants, for example, genes that confer resistance to neomycin, puromycin, hygromycin, DHFR, GPT, zeocin and histidinol are useful selectable markers. In addition to markers conferring a phenotype that allows for the discrimination of transformants based on the implementation of conditions, other types of markers including screenable markers such as GFP, whose basis is colorimetric analysis, are also contemplated. Alternatively, screenable enzymes such as herpes simplex virus thymidine kinase (tk) or chloramphenicol acetyltransferase (CAT) may be utilized. One of skill in the art would also know how to employ immunologic markers, possibly in conjunction with FACS analysis. The marker used is not believed to be important, so long as it is capable of being expressed simultaneously with the nucleic acid encoding a gene product. Further examples of selectable and screenable markers are well known to one of skill in the art.
[0106] Host Cells. As used herein, the terms “cell,” “cell line,” and “cell culture” may be used interchangeably. All of these terms also include their progeny, which is any and all subsequent generations. It is understood that all progeny may not be identical due to deliberate or inadvertent mutations. In the context of expressing a heterologous nucleic acid sequence, “host cell” refers to a prokaryotic or eukaryotic cell, and it includes any transformable organism that is capable of replicating a vector and/or expressing a heterologous gene encoded by a vector. A host cell can, and has been, used as a recipient for vectors. A host cell may be “transfected” or “transformed,” which refers to a process by which exogenous nucleic acid is transferred or introduced into the host cell. A transformed cell includes the primary subject cell and its progeny.
[0107] Host cells may be derived from prokaryotes or eukaryotes, depending upon whether the desired result is replication of the vector or expression of part or all of the vector-encoded nucleic acid sequences. Numerous cell lines and cultures are available for use as a host cell, and they can be obtained through the American Type Culture Collection (ATCC), which is an organization that serves as an archive for living cultures and genetic materials (www.atcc.org). An appropriate host can be determined by one of skill in the art based on the vector backbone and the desired result. A plasmid or cosmid, for example, can be introduced into a prokaryote host cell for replication of many vectors. Bacterial cells used as host cells for vector replication and/or expression include DH5a, JM109, and KC8, as well as a number of commercially available bacterial hosts such as SURE® Competent Cells and SOLOPACK™ Gold Cells (STRATAGENE®, La Jolla). Alternatively, bacterial cells such as E. coli LE392 could be used as host cells for phage viruses.
[0108] Examples of eukaryotic host cells for replication and/or expression of a vector include HeLa, NIH3T3, Jurkat, 293, Cos, CHO, Saos, and PC 12. Many host cells from various cell types and organisms are available and would be known to one of skill in the art. Similarly, a viral vector may be used in conjunction with either a eukaryotic or prokaryotic host cell, particularly one that is permissive for replication or expression of the vector.
[0109] Some vectors may employ control sequences that allow it to be replicated and/or expressed in both prokaryotic and eukaryotic cells. One of skill in the art would further understand the conditions under which to incubate all of the above described host cells to maintain them and to permit replication of a vector. Also understood and known are techniques and conditions that would allow large-scale production of vectors, as well as production of the nucleic acids encoded by vectors and their cognate polypeptides, proteins, or peptides.
[0110] Expression Systems. Numerous expression systems exist that comprise at least a part or all of the compositions discussed above. Prokaryote- and/or eukaryote-based systems can be employed for use with the present invention to produce nucleic acid sequences, or their cognate polypeptides, proteins and peptides. Many such systems are commercially and widely available.
[0111] The insect cell/baculovirus system can produce a high level of protein expression of a heterologous nucleic acid segment, and which can be bought, for example, under the name MAXBAC® 2.0 from INVITROGEN® and BACPACK™ BACULOVIRUS EXPRESSION SYSTEM FROM CLONTECH®.
[0112] Other examples of expression systems include STRATAGENE®'s COMPLETE CONTROL™ Inducible Mammalian Expression System, which involves a synthetic ecdysone-inducible receptor, or its pET Expression System, an E. coli expression system. Another example of an inducible expression system is available from INVITROGEN®, which carries the T-REX™ (tetracycline-regulated expression) System, an inducible mammalian expression system that uses the full-length CMV promoter. INVITROGEN® also provides a yeast expression system called the Pichia methanolica Expression System, which is designed for high-level production of recombinant proteins in the methylotrophic yeast Pichia methanolica . One of skill in the art would know how to express a vector, such as an expression construct, to produce a nucleic acid sequence or its cognate polypeptide, protein, or peptide.
[0113] Mutagenesis. Where employed, mutagenesis will be accomplished by a variety of standard, mutagenic procedures. Mutation is the process whereby changes occur in the quantity or structure of an organism. Mutation can involve modification of the nucleotide sequence of a single gene, blocks of genes or whole chromosome. Changes in single genes may be the consequence of point mutations which involve the removal, addition or substitution of a single nucleotide base within a DNA sequence, or they may be the consequence of changes involving the insertion or deletion of large numbers of nucleotides.
[0114] Mutations can arise spontaneously as a result of events such as errors in the fidelity of DNA replication or the movement of transposable genetic elements (transposons) within the genome. They also are induced following exposure to chemical or physical mutagens. Such mutation-inducing agents include ionizing radiations, ultraviolet light and a diverse array of chemical such as alkylating agents and polycyclic aromatic hydrocarbons all of which are capable of interacting either directly or indirectly (generally following some metabolic biotransformations) with nucleic acids. The DNA lesions induced by such environmental agents may lead to modifications of base sequence when the affected DNA is replicated or repaired and thus to a mutation. Mutation also can be site-directed through the use of particular targeting methods.
[0115] Site-Directed Mutagenesis. Structure-guided site-specific mutagenesis represents a powerful tool for the dissection and engineering of protein-ligand interactions. The technique provides for the preparation and testing of sequence variants by introducing one or more nucleotide sequence changes into a selected DNA.
[0116] Site-specific mutagenesis uses specific oligonucleotide sequences which encode the DNA sequence of the desired mutation, as well as a sufficient number of adjacent, unmodified nucleotides. In this way, a primer sequence is provided with sufficient size and complexity to form a stable duplex on both sides of the deletion junction being traversed. A primer of about 17 to 25 nucleotides in length is preferred, with about 5 to 10 residues on both sides of the junction of the sequence being altered.
[0117] The technique typically employs a bacteriophage vector that exists in both a single-stranded and double-stranded form. Vectors useful in site-directed mutagenesis include vectors such as the M13 phage. These phage vectors are commercially available and their use is generally well known to those skilled in the art. Double-stranded plasmids are also routinely employed in site-directed mutagenesis, which eliminates the step of transferring the gene of interest from a phage to a plasmid.
[0118] In general, one first obtains a single-stranded vector, or melts two strands of a double-stranded vector, which includes within its sequence a DNA sequence encoding the desired protein or genetic element. An oligonucleotide primer bearing the desired mutated sequence, synthetically prepared, is then annealed with the single-stranded DNA preparation, taking into account the degree of mismatch when selecting hybridization conditions. The hybridized product is subjected to DNA polymerizing enzymes such as E. coli polymerase I (Klenow fragment) in order to complete the synthesis of the mutation-bearing strand. Thus, a heteroduplex is formed, wherein one strand encodes the original non-mutated sequence, and the second strand bears the desired mutation. This heteroduplex vector is then used to transform appropriate host cells, such as E. coli cells, and clones are selected that include recombinant vectors bearing the mutated sequence arrangement. Comprehensive information on the functional significance and information content of a given residue of protein can best be obtained by saturation mutagenesis in which all 19 amino acid substitutions are examined. The shortcoming of this approach is that the logistics of multi-residue saturation mutagenesis are daunting. Hundreds, and possibly even thousands, of site specific mutants must be studied. However, improved techniques make production and rapid screening of mutants much more straightforward.
[0119] Dosage and Formulation. The composition (active ingredients; herein, vectors comprising a promoter; a nucleotide sequence encoding growth hormone releasing hormone (“GHRH”) and a 3′ untranslated region operatively linked sequentially at appropriate distances for functional expression) of this invention can be formulated and administered to affect a variety of growth deficiency states by any means that produces contact of the active ingredient with the agent's site of action in the body of an animal. The composition of the present invention is defined as a vector containing a nucleotide sequence encoding the compound of the invention, which is an amino acid sequence analog herein described. Said composition is administered in sufficient quantity to generate a therapeutically effective amount of said compound. One skilled in the art recognizes that the terms “administered” and “introduced” can be used interchangeably. They can be administered by any conventional means available for use in conjunction with pharmaceuticals, either as individual therapeutic active ingredients or in a combination of therapeutic active ingredients. In a preferred embodiment the active ingredient is administered alone or in a buffer such as PBS, but may be administered with a pharmaceutical carrier selected on the basis of the chosen route of administration and standard pharmaceutical practice. Such pharmaceutical compositions can be used for therapeutic or diagnostic purposes in clinical medicine, both human and veterinary. For example, they are useful in the treatment of growth-related disorders such as hypopituitary dwarfism resulting from abnormalities in growth hormone production. Furthermore they can also be used to stimulate the growth or enhance feed conversion efficiency of animals raised for meat production, to enhance milk production, and stimulate egg production.
[0120] The dosage administered comprises a therapeutically effective amount of active ingredient and will, of course, vary depending upon known factors such as the pharmacodynamic characteristics of the particular active ingredient and its mode and route of administration; type of animal; age of the recipient; sex of the recipient; reproductive status of the recipient; health of the recipient; weight of the recipient; nature and extent of symptoms; kind of concurrent treatment; frequency of treatment; and the effect desired. Appropriate dosages of the vectors of the invention to be administered will vary somewhat depending on the individual subject and other parameters. The skilled practitioner will be able to determine appropriate dosages based on the known circulating levels of growth hormone associated with normal growth and the growth hormone releasing activity of the vector. As is well known in the art, treatment of a female or mother to produce bigger animals will necessitate varying dosages from individual to individual depending upon the degree of levels of increase of growth hormone production required.
[0121] Thus, there is provided in accordance with this invention a method of increasing growth of an offspring which comprises administering to the female or mother of the offspring an amount of the analog of this invention sufficient to increase the production of growth hormone to levels greater than that which is associated with normal growth. Normal levels of growth hormone vary considerably among individuals and, for any given individual, levels of circulating growth hormone vary considerably during the course of a day.
[0122] Plasmid mediated gene supplementation and its vivo expression. Recently, the delivery of specific genes to somatic tissue in a manner that can correct inborn or acquired deficiencies and imbalances was proved to be possible. Gene-based drug delivery offers a number of advantages over the administration of recombinant proteins. These advantages include the conservation of native protein structure, improved biological activity, avoidance of systemic toxicities, and avoidance of infectious and toxic impurities. In addition, plasmid mediated gene supplementation allows for prolonged exposure to the protein in the therapeutic range, because the newly secreted protein is present continuously in the blood circulation.
[0123] Although not wanting to be bound by theory, the primary limitation of using recombinant protein is the limited availability of protein after each administration. Plasmid mediated gene supplementation using injectable DNA plasmid vectors overcomes this, because a single injection into the subject's skeletal muscle permits physiologic expression for extensive periods of time. Injection of the vectors can promote the production of enzymes and hormones in animals in a manner that more closely mimics the natural process. Furthermore, among the non-viral techniques for gene transfer in vivo, the direct injection of plasmid DNA into muscle tissue is simple, inexpensive, and safe.
[0124] In a plasmid based expression system, a non-viral gene vector may be composed of a synthetic gene delivery system in addition to the nucleic acid encoding a therapeutic gene product. In this way, the risks associated with the use of most viral vectors can be avoided. The non-viral expression vector products generally have low toxicity due to the use of “species-specific” components for gene delivery, which minimizes the risks of immunogenicity generally associated with viral vectors. Additionally, no integration of plasmid sequences into host chromosomes has been reported in vivo to date, so that this type of gene transfer should neither activate oncogenes nor inactivate tumor suppressor genes. As episomal systems residing outside the chromosomes, plasmids have defined pharmacokinetics and elimination profiles, leading to a finite duration of gene expression in target tissues.
[0125] Efforts have been made to enhance the delivery of plasmid DNA to cells by physical means including electroporation, sonoporation, and pressure. Injection by electroporation involves the application of a pulsed electric field to create transient pores in the cellular membrane without causing permanent damage to the cell, which allows for the introduction of exogenous molecules. By adjusting the electrical pulse generated by an electroporetic system, nucleic acid molecules can travel through passageways or pores in the cell that are created during the procedure. The electroporation technique has been used previously to transfect tumor cells after injection of plasmid DNA, or to deliver the antitumoral drug bleomycin to cutaneous and subcutaneous tumors. Electroporation also has been used in rodents and other small animals (Mir, et al., 1998; Muramatsu, et al., 1998). Advanced techniques of intramuscular injections of plasmid DNA followed by electroporation into skeletal muscle have been shown to lead to high levels of circulating growth hormone releasing hormone (“GHRH”) (Draghia-Akli, et al., 1999).
[0126] The ability of electroporation to enhance plasmid uptake into the skeletal muscle has been well documented, as described above. In addition, plasmid formulated with poly-L-glutamate (“PLG”) or polyvinylpyrolidone (PVP) has been observed to increase gene transfection and consequently expression to up to 10 fold into mice, rats and dog muscle. Although not wanting to be bound by theory, PLG will increase the transfection of the plasmid during the electroporation process, not only by stabilizing the plasmid DNA, and facilitating the intracellular transport through the membrane pores, but also through an active mechanism. For example, positively charged surface proteins on the cells could complex the negatively charged PLG linked to plasmid DNA through protein-protein interactions. When an electric field is applied, the surface proteins reverse direction and actively internalize the DNA molecules, which substantially increases the transfection efficiency.
[0127] The use of directly injectable DNA plasmid vectors has been limited in the past. The inefficient DNA uptake into muscle fibers after simple direct injection has led to relatively low expression levels, ant the duration of the transgene expression has been short. The most successful previous clinical applications have been confined to vaccines.
[0128] Although there are references in the art directed to electroporation of eukaryotic cells with linear DNA, these examples illustrate transfection into cell suspensions, cell cultures, and the like, and the transfected cells are not present in a somatic tissue.
[0129] Where appropriate, the plasmid mediated gene supplementation vectors can be formulated into preparations in solid, semisolid, liquid or gaseous forms in the ways known in the art for their respective route of administration. Means known in the art can be utilized to prevent release and absorption of the composition until it reaches the target organ or to ensure timed-release of the composition. A pharmaceutically acceptable form should be employed which does not ineffectuate the compositions of the present invention. In pharmaceutical dosage forms, the compositions can be used alone or in appropriate association, as well as in combination, with other pharmaceutically active compounds.
[0130] Accordingly, the pharmaceutical composition of the present invention may be delivered via various routes and to various sites in an animal body to achieve a particular effect (see, e.g., Rosenfeld et al. (1991); Rosenfeld et al., (1991a); Jaffe et al., 1992). One skilled in the art will recognize that although more than one route can be used for administration, a particular route can provide a more immediate and more effective reaction than another route. Local or systemic delivery can be accomplished by administration comprising application or instillation of the formulation into body cavities, inhalation or insufflation of an aerosol, or by parenteral introduction, comprising intramuscular, intravenous, peritoneal, subcutaneous, intradermal, as well as topical administration.
[0131] One skilled in the art recognizes that different methods of delivery may be utilized to administer a vector into a cell. Examples include: (1) methods utilizing physical means, such as electroporation (electricity), a gene gun (physical force) or applying large volumes of a liquid (pressure); and (2) methods wherein said vector is complexed to another entity, such as a liposome or transporter molecule.
[0132] Accordingly, the present invention provides a method of transferring a therapeutic gene to a host, which comprises administering the vector of the present invention, preferably as part of a composition, using any of the aforementioned routes of administration or alternative routes known to those skilled in the art and appropriate for a particular application. Effective gene transfer of a vector to a host cell in accordance with the present invention to a host cell can be monitored in terms of a therapeutic effect (e.g. alleviation of some symptom associated with the particular disease being treated) or, further, by evidence of the transferred gene or expression of the gene within the host (e.g., using the polymerase chain reaction in conjunction with sequencing, Northern or Southern hybridizations, or transcription assays to detect the nucleic acid in host cells, or using immunoblot analysis, antibody-mediated detection, mRNA or protein half-life studies, or particularized assays to detect protein or polypeptide encoded by the transferred nucleic acid, or impacted in level or function due to such transfer).
[0133] These methods described herein are by no means all-inclusive, and further methods to suit the specific application will be apparent to the ordinary skilled artisan. Moreover, the effective amount of the compositions can be further approximated through analogy to compounds known to exert the desired effect.
[0134] Furthermore, the actual dose and schedule can vary depending on whether the compositions are administered in combination with other pharmaceutical compositions, or depending on interindividual differences in pharmacokinetics, drug disposition, and metabolism. Similarly, amounts can vary in in vitro applications depending on the particular cell line utilized (e.g., based on the number of vector receptors present on the cell surface, or the ability of the particular vector employed for gene transfer to replicate in that cell line). Furthermore, the amount of vector to be added per cell will likely vary with the length and stability of the therapeutic gene inserted in the vector, as well as the nature of the sequence, and is particularly a parameter which needs to be determined empirically, and can be altered due to factors not inherent to the methods of the present invention (for instance, the cost associated with synthesis). One skilled in the art can easily make any necessary adjustments in accordance with the exigencies of the particular situation.
[0135] It is an object of the present invention that a single administration of a growth hormone releasing hormone is sufficient for multiple gestation periods and also provides a therapy that enhances the offspring's performances by enlarging the size of the pituitary gland and increasing the levels of prolactin.
[0136] The invention may be better understood with reference to the following examples, which are representative of some of the embodiments of the invention, and are not intended to limit the invention.
Example 1
GHRH Super-Active Analogs Increase GH Secretagogue Activity and Stability
[0137] GHRH has a relatively short half-life of about 12 minutes in the circulatory systems of both humans (Frohman et al., 1984) and pigs. By employing GHRH analogs that prolong its biological half-life and/or improve its GH secretagogue activity, enhanced GH secretion is achieved. Plasmid vectors containing the muscle specific synthetic promoter SPc5-12 (SEQ ID#7)were previously described (Li, et al., 1999). Wild type and mutated procrine GHRH cDNAs were generated by site directed mutagenesis of GHRH cDNA (SEQ ID#9) (Altered Sites II in vitro Mutagenesis System, Promega, Madison, Wis.), and cloned into the BamHI/Hind III sites of pSPc5-12, to generate pSP-wt-GHRH (SEQ ID#15), or pSP-HV-GHRH (SEQ ID#11), respectively. The 3′ untranslated region (3′UTR) of growth hormone was cloned downstream of GHRH cDNA. The resultant plasmids contained mutated coding region for GHRH, and the resultant encoded amino acid sequences were not naturally present in mammals. Several different plasmids that encoded different mutated amino acid sequences of GHRH or functional biological equivalent thereof are as follows:
[0000]
Plasmid
Encoded Amino Acid Sequence
wt-GHRH
YA DAIFT N SYRKVL G QLSARKLLQDI MS RQQGERNQEQGA-OH
(SEQID#10)
HV-GHRH
HV DAIFT N SYRKVL A QLSARKLLQDI LN RQQGERNQEQGA-OH
(SEQID#11)
TI-GHRH
YI DAIFTNSYRKVL A QLSARKLLQDI LN RQQGERNQEQGA-OH
(SEQID#12)
TV-GHRH
YV DAIFTNSYRKVL A QLSARKLLQDT LN RQQGERNQEQGA-OH
(SEQID#13)
15/27/28-GHRH
YA DAIFTNSYRKVL A QLSARKLLQDI LN RQQGERNQEQGA-OH
(SEQID#14)
[0138] In general, the encoded GHRH or functional biological equivalent thereof is of formula:
[0000] (SEQID#6) - X 1 - X 2 -DAIFTNSYRKVL- X 3 -QLSARKLLQDI- X 4 - X 5 -RQQGERNQEQGA-OH
wherein: X 1 is a D- or L-isomer of an amino acid selected from the group consisting of tyrosine (“Y”), or histidine (“H”); X 2 is a D- or L-isomer of an amino acid selected from the group consisting of alanine (“A”), valine (“V”), or isoleucine (“I”); X 3 is a D- or L-isomer of an amino acid selected from the group consisting of alanine (“A”) or glycine (“G”); X 4 is a D- or L-isomer of an amino acid selected from the group consisting of methionine (“M”), or leucine (“L”); X 5 is a D- or L-isomer of an amino acid selected from the group consisting of serine (“S”) or asparagines (“N”).
[0139] Although not wanting to be bound by theory, the X 3 position contains a Gly15 that was substituted for Ala15 to increase α-helical conformation and amphiphilic structure to decrease cleavage by trypsin-like enzymes (Su et al., 1991). GHRH analogs with Ala15 substitutions display a 4-5 fold greater affinity for the GHRH receptor (Campbell et al., 1991). To reduce loss of biological activity due to oxidation of the Met, with slightly more stable forms using molecules with a free COOH-terminus (Kubiak et al., 1989), substitution of X 4 and X 5 , Met27 and Ser28 for Leu27 and Asn28 was performed. Thus, a triple amino acid substitution mutant denoted as GHRH-15/27/28 was formed. Dipeptidyl peptidase IV is the prime serum GHRH degradative enzyme (Walter et al., 1980; Martin et al., 1993). The X 1 and X 2 substitutions can be described as poorer dipeptidase substrates were created by taking GHRH15/27/28 and then by replacing Ile2 with Ala2 (GHRH-TI) or with Val2 (GHRH-TV), or by converting Tyr1 and Ala2 for His1 and Val2.
[0140] In terms of “functional biological equivalents”, it is well understood by the skilled artisan that, inherent in the definition of a “biologically functional equivalent” protein and/or polynucleotide, is the concept that there is a limit to the number of changes that may be made within a defined portion of the molecule while retaining a molecule with an acceptable level of equivalent biological activity. Functional biological equivalents are thus defined herein as those proteins (and polynucleotides) in selected amino acids (or codons) may be substituted. A peptide comprising a functional biological equivalent of GHRH is a polypeptide that has been engineered to contain distinct amino acid sequences while simultaneously having similar or improved biologically activity when compared to GHRH. For example one biological activity of GHRH is to facilitate growth hormone (“GH”) secretion in the subject.
Example 2
DNA Constructs
[0141] In a specific embodiment, a plasmid of pSPc5-12-HV-GHRH is utilized in the present invention. In another specific embodiment, a plasmid vector is utilized wherein the plasmid comprises a pVC0289 backbone; a promoter, such as of a GHRH cDNA, such as the porcine HV-GHRH (the mutated HV-GHRH cDNA); and a 3′ untranslated region (“UTR”), such as from human growth hormone (“hGH”).
[0142] To test the biological potency of the mutated porcine GHRH cDNA sequences, plasmid vectors were engineered that were capable of directing the highest level of skeletal muscle-specific gene expression by a synthetic muscle promoter, SPc5-12, which contains proximal serum response elements from skeletal α-actin (SREs), multiple MEF-2 sites, multiple MEF-1 sites, and TEF-1 binding sites (Li, et al., 1999). A 228-bp fragment of porcine GHRH, which encodes the 31 amino acid signal peptide and the entire mature peptide porcine GHRH (Tyr1-Gly40) and or the GHRH mutants, followed by the 3′ untranslated region of human GH cDNA, were incorporated into myogenic GHRH expression vectors by methods well known in the art. The plasmid pSPc5-12 contains a 360 bp SacI/BamHI fragment of the SPc5-12 synthetic promoter (Li, et al., 1999) in the SacI/BamHI sites of pSK-GHRH backbone (Draghia-Akli et al., 1997).
[0143] The wild type and mutated porcine GHRH cDNAs were obtained by site directed mutagenesis of human GHRH cDNA utilizing the kit Altered Sites II in vitro Mutagenesis System (Promega; Madison, Wis.). The human GHRH cDNA was subcloned as a BamHI-Hind III fragment into the corresponding sites of the pALTER Promega vector and mutagenesis was performed according to the manufacturer's directions. The porcine wild type cDNA was obtained from the human cDNA by changing the human amino acids 34 and 38 using the primer of nucleic acid sequence: (5′-A-G-G-C-A-G-C-A-G-G-G-A-G-A-G-A-G-G-A-A-C-C-A-A-G-A-G-C-A-A-G-GA-G-C-A-T-A-A-T-G-A-C-T-G-C-A-G-3′). The porcine HV mutations were made with the primer of nucleic acid sequence: (5′-A-C-C-C-T-C-A-G-G-A-T-G-C-G-G-C-G-G-C-A-C-G-T-A-G-A-T-G-C-C-A-T-C-T-T-C-A-C-C-A-A-C-3′). The porcine 15Ala mutation was made with the primer of nucleic acid sequence: (5′-C-G-G-A-A-G-G-T-G-C-T-G-G-C-C-C-A-G-C-T-G-T-C-C-G-C-C-3′). The porcine 27Leu28Asn mutation was made with the primer of nucleic acid sequence: (5′-C-T-G-C-T-C-C-A-G-G-A-C-A-T-C-C-T-G-A-A-C-A-G-G-C-A-G-C-A-G-G-G-A-G-A-G-3′). Following mutagenesis the resulting clones were sequenced to confirm correctness and subsequently subcloned into the BamHI/Hind III sites of pSK-GHRH described in this Example by methods well known to those in the art. Another plasmid that was utilized included the pSP-SEAP construct that contains the SacI/HindIII SPc5-12 fragment, SEAP gene and SV40 3′UTR from pSEAP-2 Basic Vector (Clontech Laboratories, Inc., Palo Alto, Calif.). Plasmids were grown in E. coli DH5α (Gibco BRL, Carlsbad, Calif.). Endotoxin-free plasmid (Qiagen Inc., Chatsworth, Calif., USA) preparations were diluted to 1 mg/ml in PBS, pH 7.4.
[0144] The plasmids described above do not contain polylinker, IGF-I gene, a skeletal alpha-actin promoter or a skeletal alpha actin 3′ UTR/NCR. Furthermore, these plasmids were introduced by muscle injection, followed by in vivo electroporation, as described below.
Example 3
Intramuscular Injection of Plasmid and Electroporation
[0145] The nucleic acid constructs that were used in pregnant female rats are shown in FIG. 1 . Timed-pregnant Wistar female rats were housed and cared for in the animal facility of Baylor College of Medicine, Houston, Tex. Animals were maintained under environmental conditions of 10 h light/14 h darkness, in accordance with NIH Guide, USDA and Animal Welfare Act guidelines, and the protocol was approved by the Institutional Animal Care and Use Committee. The experiment was repeated twice. On day 16 of gestation, dams (n=20/group) were weighed and anesthetized using a combination of 42.8 mg/ml ketamine, 8.2 mg/ml xylazine and 0.7 mg/ml acepromazine, administered i.m. at a dose of 0.5-0.7 ml/kg. The left tibialis anterior muscle was injected with 30 μg of pSP-HV-GHRH (SEQ ID#11) in 100 μl PBS using 0.3 cc insulin syringes (Becton-Dickinson, Franklin Lakes, N.J.). Control dams were injected with a similar construct driving the reporter, beta-galactosidase. For both groups, the injection was followed by caliper electroporation, as described previously (Draghia-Akli, et al. 1999). Briefly, two minutes after injection, the rat leg was placed between a two needles electrode, 1 cm in length, 26 gauge, 1 cm between needles (Genetronics, San Diego, Calif.) and electric pulses were applied. Three 60-ms pulses at a voltage of 100 V/cm were applied in one orientation, then the electric field was reversed, and three more pulses were applied in the opposite direction. The pulses were generated with a T-820 Electro Square Porator (Genetronics, San Diego, Calif.).
Example 4
Increased Body Weight for Offspring of Injected Dams
[0146] All injected dams gave birth at 20-22 days of gestation. In the first study 240 offspring and in the second study 60 offspring were analyzed from two weeks of age to 5 months of age (2, 3, 6, 8, 12, 16, 24 weeks after birth). Body weights were recorded at these time points using the same calibrated balance. The average number of pups per litter was similar between groups (pregnant rats treated with GHRH (“I”), n=10.8±0.75 pups/litter; controls (“C”) n=11.75±0.5 pups/litter). At birth litter size was adjusted to equalize the numbers of pups to 10 pups/dam.
[0147] At 2 weeks of age, the increased postnatal growth in offspring from dams treated with the nucleic acid constructs pSP-HV-GHRH (SEQ ID#11) (“I”) and beta-galactosidase (“β-gal”) (“C”) were determined. Thus, at two weeks of age, the average pup weight was 9% greater for the offspring of I dams compared to C dams: I=31.47±0.52 g/pup vs. C=28.86±0.75 g/pup, p<0.014. At 3 weeks of age, were determined and shown in FIG. 2 . Body weights for the female offspring of pSP-HV-GHRH (SEQ ID#11) treated dams (“IF”) was significantly increased (i.e. 51.97±0.83 g) when compared to the control females offspring (“CF”) (47.07±4.4 g, p<0.043). Male offspring from pSP-HV-GHRH (SEQ ID#11) treated dams (“IM”) treated dams were 22% higher (i.e. 60.89±1.02 g) when compared to male offspring from control treated dams (“CM”) (i.e. 49.85±4.9 g, p<0.001), as shown in FIG. 2 . The weight difference was maintained up to 10 weeks of age. However, at 24 weeks of age, the weight differences between IM and CM was not significant. Significant weight differences (*) for both sexes were recorded at 3 weeks of age (p<0.05), and at 10 weeks of age (p<0.05). Female offspring from β-gal treated control dams (“CF”); female offspring of sp-HV-GHRH-treated dams—(“IF”), male offspring from β-gal treated control dams (“CM”); male offspring of sp-HV-GHRH-treated dams—(“IM”).
[0148] The difference in weight between the progeny of treated and untreated dams was maintained to adulthood. Although not wanting to be bound by theory, this difference in weight was attributable largely to enhanced growth of the musculature, which in the female offspring was maintained for the entire period of the study (24 weeks). In male progeny, the higher muscle-to-body weight ratio was maintained only to puberty. This gender difference might be explained by differences in the hormonal profile of the two sexes. Males and females have similar amounts of testosterone until puberty, at which time testosterone levels increase much more dramatically in males (Tipton, et al., 2001). Although not wanting to be bound by theory, it is well-known that the postpubertal gonadal steroid environment plays an important role in determining anterior pituitary hormone synthesis and cellular composition. High testosterone levels present in post-puberal rodent may blunt the effect of increased GH production on the skeletal muscle. The rapid increase in muscle mass in the postnatal “growing phase” is due to growth of the muscle in both longitudinal and cross-sectional dimensions. The remaining increase in muscle mass in the “steady phase” (after the 10th week) is caused entirely by transverse growth, depending mainly on the muscle fiber hypertrophy (but may include increase of connective tissues) (Tamaki, et. al., 1995).
Example 4
Increased Body/Muscle Weight for Offspring of Injected Dams
[0149] At the end of the experiment animals were anesthetized, blood was collected by cardiac puncture, centrifuged immediately at 2° C., and stored at −80° C. prior to analysis. Organs (heart, liver, spleen, kidney, pituitary, brain, adrenals, skeletal muscles—tibialis anterior (“TA”), gastrocnemius (“G”), soleus (“S”), and extensor digitorum longus (“EDL”)) from the offspring of treated and control dams were removed, weighed on an analytical balance and snap frozen in liquid nitrogen. The tibia was dissected and length was measured to the nearest 0.1 mm using calipers. Organ weight/total body weight was similar in between T and C at all time points after 3 weeks. At the first time point tested (3 weeks) the liver weight/total body weight (TM 0.042±0.0007 versus CM 0.035±0.002, p<0.0004, and TF 0.0404±0.0005 versus CF 0.0355±0.0008, p<0.0002) and the adrenal weight/total body weight (TM 4.4×10 −4 ±1.8×10 −5 , versus CM 3.6×10 −4 ±1.7×10 −5 , p<0.03, and TF 4.3×10 4 ±0.9×10 −5 , versus CF 3.2×10 −4 ±3.5×10 −5 , p<0.0003) were increased in the offspring of the T dams. No differences in between organ weights/total body weights were noticed at subsequent time points analyzed. No associated pathology was observed in any of the animals through the entire period of the study.
[0150] In contrast, both male and female offspring from pSP-HV-GHRH (SEQ ID#11) treated dams had muscle hypertrophy at 3 weeks of age with 10-12% differences in the gastrocnemius (“G”) and tibialis anterior (“TA”) muscle weights, even after the differences in body weights were adjusted. Gastrocnemius weight/body weight (“G/wt”); Tibialis anterior weight/body weight (“TA/wt”), wherein the differences were significant at *=p<0.02; #=p<0.008;°=p<0.01, as shown in FIG. 3 . At 24 weeks of age the female offspring IF of the pSP-HV-GHRH (SEQ ID#11) treated dams maintained their muscle hypertrophy, whereas males IM were similar to controls.
Example 5
Increased Serum IGF-I Levels for Offspring of Injected Dams
[0151] An indication of increased systemic levels of GHRH and GH is an increase in serum IGF-I concentration. Serum rat IGF-I was significantly higher in offspring of T dams compared to those from C dams at all time points tested until 24 weeks. FIG. 4 shows the table and histogram of the fold activation of IGF-I levels in offspring from sp-HV-GHRH-treated dams over the fold activation of the offspring from β-gal treated dams at 3, 12, and 24, weeks of age of the offspring. The circulating IGF-I levels were measured by specific rat radioimmunoassay (“RIA”). The histogram depicts fold IGF-I between age and sex matched controls, wherein the values are significant (*) at p<0.05. Female offspring from β-gal treated control dams (“CF”); female offspring of sp-HV-GHRH-treated dams—(“IF”), male offspring from β-gal treated control dams (“CM”); male offspring of sp-HV-GHRH-treated dams—(“IM”). Although not wanting to be bound by theory, the normal mechanisms responsible for the increase in serum GH levels that occur during pregnancy include: an increase in GH gene expression in the pituitary, a decrease in somatostatin secretion from the hypothalamus, an increase in immunoreactive-IGF-I content in both the hypothalamus and in the pituitary, and a significant decrease in circulating IGF-I. This state of GH resistance with a higher GH/IGF-I ratio could be important in providing supplementary nutrients to the fetus during the latter part of gestation when fetal growth is most rapid (Escalada et al., 1997). Our therapy further stimulated the maternal GHRH axis, fact that may explain the increased weight of the offspring of the treated animals at two weeks of age. Although not wanting to be bound by theory, it is also postulated that a ghrelin gene expression in the pituitary is developmentally regulated, and its expression is increased following GHRH infusion; the pituitary ghrelin/GHS-R signaling system could modulate the regulation of GH secretion by GHRH (Kamegai, et. al., 2001). Although not wanting to be bound by theory, some other possible explanations include: increased placental transport of nutrients. Postnatal, the growth curve could also be changed by increased milk production in the dam. Milk and colostrums contain a variety of proteins, peptides and steroids that possess biological activity (Grosvenor, et. al., 1993), that can be absorbed in the early neonatal period (before the “gut closure”) into serum as intact and/or low-molecular weight processed forms (Gonnella, et. al., 1989). It is known that is rats, the concentration of GHRH in milk exceeds that in plasma by several fold; in addition the neonatal rat pituitary exhibits a greater sensitivity to the stimulatory effects of GHRH (Szabo, et. al., 1986). Thus, milk GHRH may function transiently to stimulate pituitary differentiation of the offspring.
Example 6
Increased Serum IGF-I Levels for Offspring of Injected Dams
[0152] As shown in FIG. 5 , both male and female offspring from pSP-HV-GHRH (SEQ ID#11) treated dams had pituitary hypertrophy at 3 and 12 weeks. The pituitary glands were dissected and weighed within the first few minutes post-mortem. Pituitary weight adjusted for body weight was significantly increased at least to 12 weeks of age; this difference was more prominent for IF. Although not wanting to be bound by theory, the increase in pituitary weight was probably due to hyperplasia of the somatotrophs and lactotrophs.
[0153] The hypothesis that GHRH has a specific hypertrophic effect on GH and prolactin secreting cells is supported by the mRNA levels and immunohistochemical experimental evidence. For example, FIG. 6A shows a Northern blot analysis of pituitary tissue from male offspring (“c3W”) from β-gal treated control dams and male (“IM3W”) and female (“IF3W”) offspring from pSP-HV-GHRH (SEQ ID#11) treated dams at 3 weeks. RNA was visualized using probes for the 18s rRNA (“18S”) loading marker; a rat growth hormone releasing hormone specific cDNA probe (“GHRH”); a growth hormone specific rat (“GH”) cDNA probe; and a rat prolactin specific cDNA probe. The intensity of the bands was determined using a Phosphoimager (Molecular Dynamics) and associated software. Histogram (6B) shows 2.5-fold increase in GH and PRL levels of the offspring from the pSP-HV-GHRH (SEQ ID#11) treated dams over the GH and PRL levels of the offspring from β-gal treated control dams. This difference in response was associated with a diminution of 20% in the endogenous rat GHRH mRNA levels.
[0154] Sections of pituitary glands were fixed immediately after dissection in 3% paraformaldehyde in PBS overnight. After fixation, samples were washed and stored in 70% ethanol until analyzed. Pituitary glands were paraffin embedded, and five micron-thick sections were cut, deparaffinized, and washed in PBS. Sections were blocked using a solution of 5% normal goat serum, 1% BSA, 0.05% Tween 20 in PBS for 1 hour at room temperature. The sections then were incubated for 2 hours at room temperature with the primary antibodies, rabbit-antirat-growth hormone (AFP5672099Rb, National Hormone and Peptide Program—NHPP) and rabbit-antirat-prolactin (AFP425-10-91 (NHPP)) diluted 1:2000 and 1:10000, respectively. After, washing off the primary antibodies, secondary peroxidase-coupled goat anti-rabbit IgG antibody (Sigma) at 1:5000 dilution was subsequently applied for 30 minutes at room temperature. Slides were washed in distilled water in between every step of the procedure. Peroxidase activity was revealed using a DAB substrate for 4 minutes (Vector laboratories, Burlingame, Calif.). Slides were counterstained with hematoxylin to visualize cell morphology and nuclei. Digital images of the slides were captured using a CoolSnap digital color camera (Roper Scientific, Tucson, Ariz.) with MetaMorph software (Universal Imaging Corporation, Downington, Pa.) and a Zeiss Axioplan 2 microscope with a (×40) objective (numerical aperture 0.75 plan).
[0155] At the same age, pituitary sections immuno-stained with a rat GH-specific antibody ( FIG. 7A ), depicted an increased number of GH-immunoreactive cells (76% versus controls 39%), with an increased amount of GH per immunoreactive somatotroph. For each animal immunoreactive cells/total number of cells was counted in at least 5 fields and averaged. Similarly, sections stained with a rat prolactin specific antibody ( FIG. 7B ), showed an increase in the number of prolactin-producing cells (25% versus 9% in controls).
[0156] In contrast to our results, previous studies conducted in GHRH transgenic animals observed a certain developmental pattern, with pituitary weight increasing mainly after the first 6 months of life, and with 70% of the glands contained grossly visible adenomas, that stained positively for GH, whereas only some showed scattered PRL staining. Although not wanting to be bound by theory, in our methods, rat dams were treated in the last trimester of gestation and pups pituitaries were most probably exposed to the hormone only a limited period of time, which determined a change in pituitary cell lineage, with somatotroph and lactotroph hyperplasia, without neoplastic changes within the pituitary.
[0157] In summary of the prior examples, enhanced animal growth occurred in offspring following a single electroporated injection of a plasmid expressing a mutated growth hormone releasing hormone (GHRH) cDNA, into the tibialis anterior muscles of pregnant female subjects. The newborn offspring from treated females were significantly bigger at birth. The longitudinal weight and body composition studies showed a difference in between the two sexes and with age. The offspring from treated females showed plasma IGF-I levels that were significantly elevated over offspring from control treated female subjects. The offspring from treated females from had larger pituitary glands, with apparent somatotroph hyperplasia and increased levels of pituitary derived hormones (e.g. GH and prolactin).
[0158] The use of recombinant GHRH, which is an upstream stimulator of GH, may be an alternate strategy to increase the size of the pituitary gland and prolactin levels in the offspring of treated mothers. However, the high cost of the recombinant peptides and the required frequency of administration currently limit the widespread use of such a recombinant treatment. These major drawbacks can be obviated by using a plasmid meditated gene supplementation method to direct the ectopic production of GHRH in pregnant females. Although not wanting to be bound by theory, similar treatments with recombinant GH or prolactin during the immediate postnatal period of the offspring will specifically increase pituitary size, increase prolactin levels, mitigate the deposition of body fat in later life, whilst enhancing lean tissue deposition, and enhancing the immune function.
[0159] By utilizing knowledge of specific pituitary/hypothalamic pathways and the functionality of extracranially secreted hormones, it is possible to treat many conditions utilizing a plasmid mediated introduction of a nucleic acid construct into a subject. Furthermore, it has been shown that some beneficial effects can be conferred to the offspring of female subjects that have been treated utilizing a plasmid mediated introduction of a nucleic acid construct, without treating the offspring directly. The consequence of the claimed supplementation method results is modification in the pituitary lineage, with an increased number of somatotrophs and lactotrophs and an increase in the prolactin levels in an offspring from the female subject. The female subject may be a mother, a female who has never been pregnant or given birth before, or a surrogate mother, such as impregnated by fetal transplantation. The benefit of this invention shows that offspring from animals that have been treated with a plasmid meditated gene supplementation method would benefit indirectly from the therapy without being individually treated. Such a method, would save a considerable amount financial resources for treating subjects, and if only mothers were treated, a reduction in the time for implementing such a therapy would also be expected.
[0160] One skilled in the art readily appreciates that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned as well as those inherent therein. Growth hormone, growth hormone releasing hormone, analogs, plasmids, vectors, pharmaceutical compositions, treatments, methods, procedures and techniques described herein are presently representative of the preferred embodiments and are intended to be exemplary and are not intended as limitations of the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention or defined by the scope of the pending claims. | The intramuscular electroporated injection of a protease-resistant growth hormone-releasing hormone (“GHRH”) cDNA into rat dams at 16 days of gestation resulted in the enhanced long-term growth of the FI offspring. The offspring were significantly heavier by one week of age and the difference was sustained to 10 weeks of age. Consistent with their augmented growth, plasma IGF-I concentration of the FI progeny was increased significantly. The pituitary gland of the offspring was significantly heavier, and contained an increased number of somatotropes (cells producing GH) and lactotrophs (prolactin-secreting cells), and is indicative of an alteration in cell lineages. These unique findings demonstrate that enhanced GHRH expression in pregnant dams can result in intergenerational growth promotion, by altering development of the pituitary gland in the offspring. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an uninterruptible DC power system, (DC UPS) and more particularly, to an uninterruptible DC power system to be served as an emergency power source which is capable of effectively reducing the line loss when applied to electric appliances attached with AC/DC switchable power suppliers (SW power).
[0003] 2. Description of the Prior Art
[0004] Utility electric power is relied on by common domestric consumers as their power source for electric appliances. In case of the occurrence of abnormal states such as power outage, an undervoltage, or a over voltage, or an abnormal frequency, the user's loads loose their power supply so that the unterruptible power system (UPS) whose battery unit normally under floating charge state from the utility source takes over the responsibility for an emergency source to supply the emergency power to those user's loads which have lost the utility power supply.
[0005] Normally, the power output of a conventional UPS is in the form of AC. The operational principle of an UPS is inputting the AC utility power by way of an AC to DC converter so as to store the DC energy in the UPS by a DC charging circuit, and then supplies the stored DC electric power to the loads by converting back to AC when the utility power is out thereby serving as a stand by power source. Meanwhile, in the aforesaid UPS scheme, the electric power is firstly converted from AC to DC, and then converted back from DC to AC, through repeated conversion of electric power as such, the electrical circuits used for such repeated conversion of power become complicated with increased circuit loss as well.
[0006] Therefore, an invention devoting to resolving aforesaid disadvantages of current UPS so as to upgrade the quality of the UPS is definitely necessary. The present inventor has delved into this matter with long time efforts and come to realization of the present invention.
SUMMARY OF THE INVENTION
[0007] It is a first object of the present invention to provide a newly developed DC UPS which is capable of reducing electric power loss during conversion so as to improve the efficiency and effectiveness of the system, and start a lighting equipment in case the utility AC voltage becomes abnormal.
[0008] It is a second object of the present invention to provide a newly developed DC UPS which is capable of maintaining a stable output voltage without being influenced by the input source.
[0009] It is a third object of the present invention to provide a newly developed DC UPS which is capable of performing power conversion by only one stage so as to minimized the complexity of the circuit scheme and also improve environmental conscious effect.
[0010] To achieve the aforesaid objects, the DC UPS of the present invention is composed of at least a AC voltage and frequency detecting circuit, an AC to DC conversion and charging circuit, a DC voltage conversion circuit, a load detecting circuit, an output voltage detecting circuit, and a control circuit. It is essentially emphasized that the invention is devoted to reducing the power loss owing to power conversion so as to improve the system efficiency and save energy. Moreover, the DC UPS of the present invention can maintain a stable output voltage, and by means of detecting utility AC voltage, a lighting equipment can be turned on to illuminate surroundings in case the utility supply voltage is found to be abnormal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The above objects and other advantages of the present invention will become more apparent by describing in detail the preferred embodiments of the present invention with reference to the attached drawings in which:
[0012] [0012]FIG. 1 is a layout scheme of the DC UPS in a first embodiment of the present invention;
[0013] [0013]FIG. 2 is a layout scheme of the DC UPS in a second embodiment of the present invention;
[0014] [0014]FIG. 3 is an electric circuit diagram of the DC UPS in a first embodiment of the present invention;
[0015] [0015]FIG. 4 is an electric circuit diagram of the DC IPS in a second embodiment of the present invention; and
[0016] [0016]FIG. 5 is an illustrative diagram in which the DC UPS of the present invention is applied to an AC/DC switchable power supplier (SW power).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] The DC UPS provided by the present invention is well applicable to an electrical appliance using the SW power as its power supplier so as to reduce circuit loss due to power conversion and improve system efficiency and saving energy by only one stage conversion.
[0018] Except the complexity in the circuit design is minimized, the invention further contributes to environmental security protection and maintaining a stable output voltage.
[0019] Referring to FIG. 1 and FIG. 3, in which a layout scheme (FIG. 1) and an electric circuit diagram (FIG. 3) of the DC USP in a first embodiment of the present invention are shown. This embodiment belongs to an ON-LINE system which essentially comprises a lighting equipment 10 , an AC voltage and frequency detecting circuit 11 , an AC to DC conversion and charging circuit 12 , a battery unit 13 , a DC voltage conversion circuit 14 , a load detecting circuit 15 , an output voltage detecting circuit 16 , an inner system power source 17 , a controller circuit 18 , and a switch 19 . So far there is an utility AC available, a signal is delivered to the controller circuit 18 from the AC voltage and frequency detecting circuit 11 to actuate the AC to DC conversion and charging circuit 12 and the switch 19 for outputting DC power and charging the battery unit 13 .
[0020] After finishing charging the battery unit 13 , a notification signal is sent to the controller circuit 18 for interrupting the charging circuit 12 so as to protect the battery unit 13 . In case the voltage, or frequency etc. of the utility AC power is found to be abnormal, the controller circuit 18 is informed by the AC voltage and frequency detecting circuit 11 of this state so as to start operation of the DC voltage conversion circuit 14 for continuously supplying power to the loads thereby attaining the uninterrupted power supply, and turn on the lighting equipment 10 to illuminate surroundings.
[0021] The inner system power source 17 is for supplying power to the inner components of UPS. Besides, the controller circuit 18 can control the output voltage at a predetermined value according to the detected results obtained by the output voltage detecting circuit 16 . And, the load detecting circuit 15 is for detecting whether there is an overloading at the output terminal and informing the controller circuit 18 of the detected results.
[0022] In the first embodiment, in addition to servicing for the electric appliances equipped with the SW power, a DC to AC inverter may be added to the present invention for supplying AC power to other appliances which have no attached SW power.
[0023] Referring to FIG. 2 and FIG. 4, in which a layout scheme (FIG. 2) and an electric circuit diagram (FIG. 4) of the UPS in a second embodiment of the present invention are shown. This embodiment belongs to an OFF-LINE system which essentially comprises a lighting equipment 20 , an AC voltage and frequency detecting and charging circuit 21 , a battery unit 22 , a DC to AC convertion circuit 23 , a load detecting circuit 24 , and output voltage detecting circuit 25 , an inner system power source 26 , a controller circuit 27 , and an electromagnetic switch 28 . So far there is an utility AC input, the AC voltage and frequency detecting and charging circuit 21 delivers a signal to the battery unit 22 informing that it is to be charged and informing the controller circuit 27 for actuating the electromagnetic switch 28 to output an AC power.
[0024] When finished charging of the battery unit 22 , a signal is sent to the controller circuit 27 to stop charging so as to protect the battery unit 22 from being overcharged. In case the voltage, or frequency etc. of the utility AC power is found to be abnormal, the controller circuit 27 is informed by the AC voltage and frequency detecting and charging circuit 21 of this state so as to start operation of the DC voltage conversion circuit 23 and the electromagnetic switch 28 continuously supplying power to the loads thereby attaining the aim of uninterrupted power supply.
[0025] The inner system power source 26 is for supplying power to the inner components of UPS. Besides, the controller circuit 27 can control the output voltage at a predetermined value according to the detected results obtained by the output voltage detecting circuit 25 . And, the load detecting circuit 24 is for detecting whether there is an overloading at the output terminal and informing the controller circuit 27 of the detected results.
[0026] In the second embodiment, in addition to servicing for the appliances equipped with the SW power, a DC to AC inverter may be added to the present invention for supplying AC power to other appliances which have no attached SW power.
[0027] Referring to the illustrative diagram shown in FIG. 5 in which the UPS of the present invention is applied to an AC/DC switchable power supplier (SW power). If the utility AC power supply is working normally, the power is stored in a battery unit 31 after AC to DC conversion. In case the utility power fails to keep its normal state which being detected by a detecting circuit 32 , a controller circuit 33 sends a signal to an electromagnetic switch 35 of a SW power 34 which actuates a DC voltage conversion circuit 36 to produce a high DC voltage. This high DC voltage is stepped down to a low voltage DC as an output power via another DC voltage conversion circuit 37 .
[0028] It emerges from the description of the above embodiments that the invention has several noteworthy advantages which are not found in any conventional UPS, in particular;
[0029] 1. The power loss in conversion is reduced which leads to energy saving and improving system efficiency.
[0030] 2. The output voltage is not affected by variation of the input voltage so that the UPS of the present invention can always maintain a stable output voltage.
[0031] 3. Power conversion is performed through only one stage so that the circuit scheme is simplified which also results in an environmental conscious effect.
[0032] 4. In addition to taking over the mission of continuously supplying power to the loads, the UPS of the present invention is capable of turning on its lighting equipment so as to illuminate surroundings.
[0033] Only two preferred embodiments of the present invention are exemplified to shown its versatility and novelty, it is to be understood that the present invention is capable of use in various other combination and environments and is capable of changes or modification within the scope of inventive concept as expressed in appended claims. | Disclosed herein is a DC uninterruptible power system which is composed of a AC voltage and frequency detecting circuit, an AC to DC conversion and charging circuit, a DC voltage conversion circuit, a load detecting circuit, an output voltage detecting circuit, and a control circuit. The UPS of the present invention can minimize the power loss due to one stage conversion so as to improve system efficiency, and maintain a stable output voltage. Beside, a lighting equipment is installed for illuminating surroundings in case the utility voltage becomes abnormal. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of pending PCT/US2008/000677 filed on Jan. 18, 2008.
TECHNICAL FIELD
[0002] The field of this invention relates to a riding apparatus for treating a floor surface with a power cord handling swing arm.
BACKGROUND OF THE DISCLOSURE
[0003] Concrete floors are common today in large, medium and small retail stores, manufacturing and production facilities, warehouses, automotive shops and service centers, shopping centers, sidewalks, garages, commercial buildings and residential basements. The strength of concrete provides the durability and rigidity required in these environments. However, the exterior surface of a newly poured concrete floor, once dry, is often rough, uneven, and provides a dull appearance. Furthermore, when left in this unfinished state, the concrete will inherently produce dust particles from the constant scuffing, whether it is from foot traffic or wheeled traffic that can build over time and become a nuisance to those who work and/or live in these environments. It is well known to first grind the concrete surface and then coat the surface with a sealant to smooth the concrete, to make it aesthetically pleasing to the eye, and to help reduce dust particles.
[0004] In the grinding process, commonly used grinding machines usually have a planetary or direct drive belt and gear drive systems containing a plurality of circular drive plates mounted to gears on a deck with removable abrasive pads attached to each drive plate. These grinding machines may also be referred to as grinding, honing, abrasive or abrading machines. They may also be referred to as polishing and cleaning machines. Hereinafter, the term “polishing and cleaning” is used in the generic sense and includes abrasion, scrubbing, sweeping, honing, grinding, sanding and/or abrading, cleaning and polishing. These types of machines can also be referred to as an apparatus for treating a floor surface. The term “treating a floor surface” as used herein can mean cleaning, abrading, sanding, scrubbing, sweeping, polishing, grinding or honing a floor surface. These polishing and cleaning machines may typically be electric walk along machines where an operator stands behind the machine and pushes it along at a certain pace such that the deck sufficiently grinds, abrades, hones, polishes and or cleans the floor surface. These walk along configurations can produce fatigue in the operator and the operator's position behind the machine prevents a clear view of the floor surface until the floor surface passes under the operator's feet well behind the deck. Thus if a spot on the floor is missed or not adequately prepared, the operator may need to back up a distance to redo the spot.
[0005] Riding polishing and cleaning machines are known but have had certain drawbacks. Firstly, some are large using standard tractor bodies powered by internal combustion gas, diesel or propane engines. The exhaust from such gasoline, diesel or propane engines makes it less desirable to use within an interior confined space. The use of internal combustion engines and hydraulic drive systems also introduces the significant probability that there may be leakage of oil, petroleum based or synthetic based lubricant or fluid onto a porous cured top layer of concrete or an even more porous substrate. Any leakage or spillage of oil, gasoline diesel fuel or grease onto the surface will be readily and permanently absorbed into the concrete and leave a permanent stain that will never yield a proper polished surface free of stains. Furthermore the oil, grease, or lubricant can contaminate the cutters or other grinding, and polishing pads or tools.
[0006] In addition, many of these machines are quite large and the operator has no view or a poor view of the floor after the deck passes over. Thus on-the-spot quality control for just prepared floor surface is extremely difficult.
[0007] Riding polishing and cleaning machines have had awkward configurations with either rear positioned seating or enclosed cab seating for the operator which blocks his view. Other machines have open high precarious seating which can make the operator feel vulnerable or unsafe in such a high open position from the floor.
[0008] Electric powered riding polishing and cleaning machines are also commercially utilized. While the wheels and vehicular controls are powered by on board rechargeable batteries, the proper high pressure, torque and speed power needed for the cleaning and abrasive deck is too demanding for present day battery technology so the electric power is provided through a power cord from a remote power supply. The power cord often intrudes in the way of the apparatus wheels and deck particularly when the ride on machine is heading in the direction back toward the power supply. A significant amount of time is spent by the operator manually getting off the vehicle to move the cord out of the way of the vehicle.
[0009] Another difficulty with the known riding polishing and cleaning machines is the difficulty in changing the grit pads or cutters when the grit pads or cutters become worn. Replacing the worn pads or cutters, or in some cases replacing the entire deck is both burdensome and time consuming to the user.
[0010] Another common problem is dust control. Often the vacuum system at the deck picks up only about 80 percent of the generated dust. The remaining dust must be picked up by a sweeping deck. Previous sweeping decks have been an integral part of the ride-on apparatus's chassis. As such when uneven flooring or an obstacle is encountered, the sweeping apparatus can be jammed or not provide the necessary ground clearance.
[0011] What is needed is a riding polishing and cleaning apparatus that allows an operator a relatively low seating position and have direct view of the floor surface behind the cleaning and abrasive deck. What is also needed is a riding polishing and cleaning apparatus that has a power cord handling system. What is also needed is a riding polishing and cleaning apparatus that has a sweeping deck that is vertically adjustable with respect to the apparatus chassis. What is also needed is a riding polishing and cleaning apparatus that has an easily liftable, tillable and disengageable polishing and cleaning deck.
SUMMARY OF THE DISCLOSURE
[0012] In accordance with one aspect of the invention, a riding apparatus for treating a floor surface has a main motorized vehicle with steering and drive wheels and a forwardly located seat for an operator and left and right foot rests for feet of the operator. A polishing and cleaning deck is mounted in front of the vehicle and is operably connected thereto to be moved thereby with a clearance formed between a front of the main motorized vehicle and a rear of the polishing and cleaning deck. The left and right foot rests are spaced apart to form a gap therebetween with the gap and the clearance aligned with the seat located for providing a line of sight for the operator through the gap and clearance to see the floor surface between the polishing and cleaning deck and the main motorized vehicle.
[0013] Preferably, the vehicle has a low profile rear body section positioned to have its upper surface located below the normal eye level of the operator when seated on the seat such that a full 360 degrees field of vision to the rear is directly available to an operator. The upper surface of the vehicle body is desirable sloped downwardly from a position immediately behind the seat to a rear end of the riding apparatus.
[0014] According to another aspect of the invention, an upper positioned swing arm is pivotably connected about a substantially vertical pivot axis point behind and above the operator seat and constructed to horizontally swing to the left and to the right of a rearwardly extending position down a center line of the main motorized vehicle. The swing arm has a length more than one-half the width of the vehicle such that the swing arm has sufficient length to extend the restrained section of the cord beyond a left and right side of the vehicle when swinging to its full left or right position. The power cord has a restrained section near a distal end of the swing arm and operably connected to the polishing and cleaning decks for transferring electric power to the deck. Preferably, the pivot is constructed to provide the swing arm to swing approximately 90 degrees to either side of the centered rearwardly extending position.
[0015] In one embodiment, the vehicle has two front wheels and a rear wheel. The rear wheel is steerable and operably connected to an electric motor for driving the vehicle. The electric motor is powered by an on-board battery source that is directly and continuously rechargeable via the main onboard power supply vehicles main power supply when powered on and during vehicle operation.
[0016] It is desirable that the polishing and cleaning deck is pivotably connected along a generally horizontal laterally extending axis to the vehicle through a front distal end of a raisable link arm such that the deck can be pivoted to a generally vertical position to expose the underside of the deck when the deck is in a raised position off of the floor surface. Preferably the link arm has a notch at a distal end and a closable latch for being movable between a closed position to retain the deck to be pivotably mounted to the link arm and an open position to allow the link arm to vertically move to disengage from the deck when in its lower floor engaging position.
[0017] According to another aspect of the invention, a riding apparatus for treating a floor surface has a sweeping deck mounted under the vehicle behind the polishing and cleaning deck through a linkage that provides relative vertical movement with respect to the vehicle. The sweeping deck comprises a motorized brush for sweeping a floor, a hopper for receiving dust from the brush and a castor wheel for providing a lower stop for the sweeping deck. Preferably, a vacuum system is operably connected to collect dust from both the polishing and cleaning deck and the hopper in the sweeping deck.
[0018] The linkage system includes a lifting actuator to raise the sweeping deck and when in a floor engaging position allows the sweeping deck to automatically lift, i.e. float upwardly, with respect to the vehicle body when encountering a raised floor surface or obstacle under the vehicle body wheels to prevent the sweep deck from jamming the roller brush.
[0019] In accordance with another aspect of the invention, a power cord handling system for a riding apparatus with a polishing and cleaning deck for treating a floor surface powered from a power cord includes an upper positioned swing arm pivotably connected to the riding apparatus about a substantially vertical pivot axis to horizontally swing the swing arm to the left and to the right of a rearwardly extending position when a torque is exerted thereon. The power cord has a restrained section near a distal end of the swing arm and operably connected for providing electric power to the polishing and cleaning deck. The swing arm has a length more than one-half the width of the vehicle such that the swing arm has sufficient length to extend beyond a left and right side of the riding apparatus when swinging to its full left or right position to position the restrained section of the power cord beyond the respective left and right side of the vehicle. A stop mechanism prevents the swing arm from further horizontal rotation beyond its full left and full right position. A remote power cord reel assembly allows the power cord to be unreeled therefrom when the riding apparatus is moving away from the reel assembly and constructed to substantially take up slack of the power cord when the riding apparatus is moving toward the reel assembly.
[0020] Preferably the reel assembly having a spring loaded rotatable reel and a weighted frame to stabilize against horizontal torque force exerted by the spring loaded reel.
[0021] In accordance with another aspect of the invention, an electric powered riding apparatus for treating a floor surface has a motorized vehicle and a power cord extendable from the apparatus to an electric source. A jointed swing arm has a proximate arm member pivotably connected about a vertical axis to the vehicle in proximity to a longitudinal center line of the vehicle. A distal arm member is pivotably connected about a pivot vertical axis to the proximate arm section and has a retainer for mounting the power cord. The distal arm member is resiliently biased to extend straight out with respect to the proximate arm member.
[0022] The swing arm is dimensioned to extend the distal arm section beyond a side of the vehicle when the swing arm extends laterally with respect to the vehicle. A spring member is connected to the distal arm member for resiliently biasing the distal arm member to extend straight out with respect to the proximate arm member against a side force below a predetermined amount and yieldable to allow bending of the distal member with a side force above the predetermined amount.
[0023] Preferably, the swing arm is dimensioned to extend at least from its pivotable connection to the vehicle to a rear corner of the vehicle. The proximate arm member has a length no more than one-half the width of the vehicle such that the pivot vertical axis is always within the side extent of the vehicle.
[0024] In one embodiment, the spring member having sufficient force to maintain the distal arm member straight with respect to the proximate arm member against normal drag forces exerted by the power cord on the floor surface and able to resiliently bend upon the distal arm member abutting against a building support column. The proximate arm member and distal arm member have a mechanical stop therebetween which stops the bending of the distal arm member at approximately 90 degrees with respect to the proximate arm member. The distal arm member has a raised arm section that overlays the proximate arm member. The raised arm member is connected to the spring member. The spring member has an opposite end connected to the proximate arm member. The spring member is preferably in the form of a gas spring having a tubular cylinder member and rod extending from the tubular cylinder member. The distal end of the distal arm member may have at least one roller member pivotably attached about a vertically oriented pivot axis.
[0025] According to another aspect of the invention, a swing arm for managing a power cord to an electric vehicle has a proximate arm member with a pivotable connection about a vertical axis for connection to the vehicle in proximity to a longitudinal center line of the vehicle. A distal arm member is pivotably connected about a pivot vertical axis to the proximate arm member and is resiliently biased to extend straight out with respect to the proximate arm member. The swing arm is dimensioned to extend the distal arm member beyond a side of the vehicle when the swing arm extends laterally with respect to the vehicle. A spring member is connected to the distal arm member for resiliently biasing the distal arm member to extend straight out with respect to the proximate arm member against a side force below a predetermined amount and yieldable to bending of the distal arm member upon exertion of a side force above the predetermined amount.
[0026] In accordance with another aspect of the invention, an electric vehicle has a power cord extendable from the vehicle to an electric source. A swing arm has a length extending a least one-half of the width of the vehicle to extend beyond a selected one of the left and right side of the vehicle when swung to a respective full left and right position from a rearwardly extending center position about a substantially vertical pivot axis point. The swing arm has a connection for retaining the power cord near a distal end of the swing arm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Reference now is made to the accompanying drawings in which:
[0028] FIG. 1 is a top perspective view showing a riding apparatus for treating a floor surface according to one embodiment of the invention with a vehicle panel removed to expose the interior;
[0029] FIG. 2 is an enlarged fragmentary view with the deck shell removed illustrating the polishing and cleaning deck and its mounting frame shown in FIG. 1 ;
[0030] FIG. 3 is a top plan view of the riding apparatus shown in FIG. 1 with the deck shell and vehicle panels removed to show the interior components;
[0031] FIG. 4 is a fragmentary bottom perspective view of the polishing and cleaning deck illustrating the vacuum hose intakes;
[0032] FIG. 5 is a side elevational view of the riding apparatus illustrating a person's field of vision and the lifting and tilting of the front deck to expose the underside of the polishing and cleaning deck;
[0033] FIG. 6 is an enlarged side elevational view illustrating the polishing and cleaning deck's connecting linkage to the main vehicle body of the riding sander;
[0034] FIG. 7 is a fragmentary side elevational view of the floating sweeping deck under the main vehicle body;
[0035] FIG. 8 is an enlarged elevational view from the other side of the sweeping deck;
[0036] FIG. 9 is a fragmentary top plan view illustrating an optional edge grinder and polisher attached to the polishing and cleaning deck;
[0037] FIG. 10 is a side elevational view illustrating the power chord connection to a take up reel and power source;
[0038] FIG. 11 is an enlarged side elevational view of the power chord reel shown in FIG. 10 ;
[0039] FIG. 12 is a top plan view schematically illustrating the position and motion of the riding apparatus and the swing arm during typical back and forth use of the riding apparatus;
[0040] FIG. 13 is a schematic side elevational view of a riding apparatus with a second embodiment of a swing arm;
[0041] FIG. 14 is an enlarged top plan view of the swing arm shown in FIG. 13 ;
[0042] FIG. 15 is a side elevational view of the swing arm shown in FIG. 14 ;
[0043] FIG. 16 is a top plan view of the proximate arm member shown in FIG. 14 ;
[0044] FIG. 17 is a top plan view of the distal arm member shown in FIG. 14 ;
[0045] FIG. 18 is a top plan view showing the distal arm member being pivoted to a 90 degrees angle with respect to the proximate arm member;
[0046] FIG. 19 is a top plan view of a third embodiment of a swing arm having three rollers on the distal arm member;
[0047] FIG. 20 is a schematic top plan view of the riding apparatus shown in FIG. 13 moving in a forward direction;
[0048] FIG. 21 is a schematic top plan view of the riding apparatus shown in FIG. 20 moving in a rearward direction and angled to change its floor line;
[0049] FIG. 22 is a schematic top plan view of the riding apparatus shown in FIG. 21 after it has moved to its new floor line and moving in a reverse direction;
[0050] FIG. 23 is a view similar to FIG. 22 where the swing arm commences abutment with a building column and the distal arm member begins to pivot toward the front of the vehicle as the vehicle moves rearwardly; and
[0051] FIG. 24 is a view similar to FIG. 23 showing the swing arm distal arm member fully pivoted to a 90 degrees position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0052] Referring now to FIG. 1 , a riding apparatus 10 for treating floor surfaces has a battery operated main vehicle body 12 , a forwardly positioned polishing and cleaning deck 14 , a sweeping deck 16 , and a swing arm 18 for a power cord 20 .
[0053] The vehicle body 12 has a forward positioned operator seat 22 with controls 24 readily positioned for hand operation to control speed, direction and other needed vehicle and deck functions and foot controls 26 , for example a brake and transmission clutch. The seat 22 is positioned over the electric batteries storage container 27 . The electric batteries 31 stored in container 27 as shown in FIG. 3 can be conventional lead acid type or any state of the art battery that powers the vehicle motion. The seat 22 is also aligned above an axis 29 defined by the two front wheels 28 .
[0054] Two foot rests 30 are positioned apart to rest the operator's left and right feet. A gap 32 is formed between the two foot rests 30 . The gap 32 is aligned over the clearance 37 between the center section of the polishing and cleaning deck 14 and the main vehicle body 12 to provide a line of sight to the floor surface. Side vented windows 33 to the inside of the front wheels 28 also provide a line of sight to the floor surface behind the left and right side sections of the front deck 14 . The side vented windows 33 have a support grate 35 that can be used as a single step for an operator 62 to access seat 22 .
[0055] As shown more clearly in FIGS. 2 , 3 , and 4 , three cleaning and abrasive heads 36 that are operated by electric motors 38 are housed within shell 34 . The electric heads 38 are powered from a remote power source delivered through a power chord as described later. The heads 36 are mounted to a deck frame 40 . The deck frame has a horizontally disposed round bar 42 which engages an operable claw end 44 of two parallel arms 46 .
[0056] As shown in FIG. 5 , the arms 46 are operated and powered to move between a lower operating position and raised service position to lower the deck 14 onto the floor surface and also to raise the deck 14 . The arms 46 may be power operated for example by hydraulic cylinders 48 through a linkage 49 between the raised and lower positions as shown in FIG. 6 . In addition, the hydraulic cylinder 48 can provide extra force in the lower position to add some of the weight of the vehicle 12 onto the deck 14 when more downward force is needed during the more aggressive grinding and abrasive operation of the deck 14 . For example, the cylinders 48 can lift the front wheels 28 off of the floor to add the weight to the deck 14 . It is foreseen that hydraulic cylinder 48 can be replaced by other types of power mechanisms, such as electrically driven devices. This use of downward force from the main vehicle eliminates the need of external weight and its associated cumbersome carrying, storing and handling.
[0057] Furthermore the frame 40 can pivot within the claw end 44 to pivot to deck 14 to a service position shown in FIG. 5 to expose the disc pad under each head and access the underside of all the disc heads 36 . A removable handle 50 may engage a horizontal grip tube 51 so that an operator can manually pivot the deck 14 . One of several types of locking devices may be engaged to keep the deck 14 in this servicing position. It is noted that the use of the single lever 50 rotates the entire deck including all three heads 36 in one pivoting motion. The deck is raised sufficiently high to assure that the side heads 36 also clear the floor during this pivoting motion. Optionally, the round tube 42 may have a cam lever thereon to be operated by a hydraulic cylinder or linear actuator for power pivoting of the deck. A linear actuator when used can double as a lock due to its worm gear ratio inherently designed therein.
[0058] As shown in FIG. 6 , the deck 14 can be disengaged from the vehicle and arms 46 by opening of the claw end 44 , further lowering of the arms 46 to clear the claw end 44 from the round bar 42 and moving the vehicle 12 rearwardly to leave the deck 14 on the floor. Before the vehicle rearward movement, the flexible central vacuum hose 52 can be disconnected as well as any quick connect wiring plugs that provide the power to the electric motors 38 . Reversing the process, reattaches the claw end 44 with the bar 42 . The claw end 44 can be retained in the closed position by a standard lock mechanism for example a clevis pin and retaining hairpin style clip. Alternatively, the claw end 44 opening and closing can be automated and further expedited for example by use of a pneumatic cylinder, electric linear actuator or a remotely operated manual linkage. In this way, the vehicle 12 quickly and can easily switch decks 14 when desired i.e. when decks have different grit pads 70 thereon or switching from a grinding and/or polishing deck to a cleaning deck. In other words, a second deck 14 may be on the floor surface ready to be engaged with the main motorized vehicle 12 after the first deck 14 is disengaged.
[0059] The round bar 42 is positioned by locating it at or near the fore and aft center of gravity of the deck 14 . The round nature of the bar 42 also allows the deck 14 to pivot thereabout to automatically become horizontal. The front claw 44 provides sufficient clearance for the bar 42 to rotate therein when the claw is in the closed and locked position. As shown with the three heads 36 as positioned, the bar is behind the electric motor 38 of the center head and slightly in front of the electric motors 38 of the left and right heads 36 to achieve the center of gravity balance.
[0060] The hydraulically operated arms 46 are operated by hydraulic cylinder 48 through linkage 49 that pivots the arms 46 about a rear connection bar 68 which lifts the entire deck 14 including the round bar 42 , all the heads 36 , and frame 40 . Furthermore as shown, easy access to abrasive pads or cutters 70 may be further enhanced by pivoting of the deck about round bar 42 to place the operating underside 72 of the deck 14 in a forward direction. The easy accessibility allows for ease in changing the pads 70 when needed.
[0061] Referring to FIG. 4 , the central vacuum hose 52 is connected to a vacuum manifold 54 . Vacuum hoses 56 connect the central manifold 54 to two similar side manifolds 58 . The manifolds 54 and 58 connect to the respective heads 36 . The central vacuum hose 52 leads to the vacuum system to the rear of the operator as described later. The vacuum manifolds 52 and 58 are in communication with the interior of heads 36 through apertures 59 .
[0062] As shown in FIG. 5 , an operator 62 is seated in a forward position at the front end of the vehicle 12 and behind the deck 14 . The vehicle is constructed to provide a greatly enhanced view of the floor surface by operator 62 . Firstly, by being up front, the operator 62 has a much better angle to see the floor surface just before it goes under the deck as indicated at 59 . Secondly, the clearance 37 between the rear of the deck 14 and the front of the vehicle 12 and the gap 32 between the foot rests 30 allow for visual viewing of the floor surface after the deck passes over behind the center abrasive head 36 to the area 59 of the floor. Thirdly, the windows 33 allow the operator 62 a line of sight to each area 61 of the floor behind the other two side heads 36 inside of wheels 28 . This visibility just behind all three heads provide real time monitoring of the floor surface and any defects that are discovered can be immediately corrected. To aid in illuminating the floor, optional lights, such as lamps 65 and others (not shown) may be installed on and under the vehicle and aimed to these floor areas 55 , 59 and 61 .
[0063] In addition, the low profile of the body 12 well below the operator's head allows for rear visibility without the need of mirrors to facilitate good vision at the corners during turns and also during rearward motion when necessary. The low profile of the entire vehicle 12 provides for the seat 22 to be relatively close to the floor but still provide a commanding view fully about the vehicle. Furthermore, the low profile provides a security measure and a feeling of safety for the operator 62 as compared to high open cockpit positions found in the prior art. For example, it is feasible to obtain the seat cushion to be 35″ to 45″ high off of floor.
[0064] As shown in FIG. 5 , the vehicle has a single rear wheel assembly 80 that is both powered and steerable to maneuver the vehicle 12 . The use of joystick 82 on the front control panel 24 can be used to steer the rear wheel. Alternatively a conventional steering wheel can also be used. One suitable drive wheel is sold under the Metalrota trademark and can give 180 degree steering or turning capability i.e. 90 degrees in each direction.
[0065] Dust control is accomplished by several separate systems. The first vacuum system picks up dust inside the bowls of grinder heads 36 through the apertures 57 as shown in FIG. 4 and through hoses 54 and 52 which are operably connected to an inlet 63 of first stage centrifugal separator 64 shown in FIG. 3 which functions as a pre-cleaner that spins the heaviest solids into a disposable bag lined container 66 . The outlet of the centrifugal separator is drawn into a four stage vacuum motor 68 whose outlet 74 is connected to an envelope filter bag 76 which filters the remaining smaller particles before the air is expelled out through the filter media to the ambient atmosphere. The filter bag 76 has filter media therein which can be cleaned by a backflush system for reversing air flow in a forceful and pulsing fashion to unplug or clean the filter media. This can be accomplished for example by an electrically driven air pump pressurizing an accumulator tank. A dump valve electrically is coupled to a 5 or 6 position switching valve which can be plumbed to the individual bag type filter media. A timer is used to time the dump valve or a pressure switch is used to empty the accumulator tank.
[0066] A second dust controller includes a sweeping deck 16 suspended under the vehicle 12 . As shown more clearly in FIGS. 7 and 8 , the sweeping deck 16 includes a frame 84 that is suspended via cables 86 or parallel rods to the vehicle 12 . A hopper 88 is mounted under the frame and has an open side 89 facing a powered roller brush 90 . The hopper 88 is also connected to the vacuum system to evacuate the dust therein to the vacuum system as described above and maintain the hopper in a condition for receiving more dust from the roller brush. The size of the hopper can thus be significantly reduced to an amount correlated with higher CFM (Cubic Feet per Minute) rated vacuums. The roller brush 90 is powered by a motor 92 mounted to the broom arm 94 and belt driven thereby. The broom arm 94 is pivotably adjustable through a wear adjustment knob 96 to maintain proper contact of the brush to the floor as the bush wears and its diameter decreases as shown in phantom in FIG. 8 . The open side 89 may be closed by a door panel 91 when the apparatus is wet scrubbing to prevent wet slurry from entering the hopper 88 .
[0067] The entire sweeping deck can be lifted by an actuator 98 that is connected to the frame 84 through a non rigid cable 100 . The non rigid connection allows the rear caster 102 to act as a stop. The non rigid cable 100 prevents the actuator from overloading the casters or the deck would fail to be in the proper position to the floor. In addition should a collision object be encountered by the sweeping deck, the non rigid link 100 allows the entire sweep deck to float over the collision object and thereby minimize damage. Alternatively, the non rigid cable 100 may be replaced by a rigid linkage that is connected via a vertical oriented slot that allows relative vertical movement between the linkage and either the actuator or the sweeping deck 16 to accomplish the same effect. Furthermore, the sweeping deck 16 if damaged can be easily removed from the existing machined for ease of service without disabling the remainder of the vehicle 12 . A replacement sweeping deck can be easily substituted for a damaged one if necessary.
[0068] Dust wipers (e.g. elastomeric squeegees or brushes) 105 are mounted in front of each front wheel 28 to direct dust inwardly to the inside track of the front wheels 28 . Thus the wheels 28 track through less dust and the dust is directed toward the sweeping deck and roller brush 90 . The wipers may be mounted approximately 45 degrees away from the line of travel to redirect the dust inwardly.
[0069] A rear seal assembly 104 includes a recirculation flap 106 and a rear flap 108 both mounted to a hook frame 110 . The rear seal assembly 104 can then be suspended behind the sweeping deck and engaged onto a hanger hook 112 on the sub frame 84 which temporarily holds the rear seal assembly 104 in place until two retaining bolts or pins (not shown) are installed which secure the rear seal assembly 104 in its engaged position. The subassembly 104 can thus be easily removed and installed and the removed assembly 104 can be worked on away from the vehicle 12 in a convenient location rather than under the vehicle.
[0070] An optional edge grinder as shown in FIG. 9 can further increase the efficiency of the riding sander. The edge grinder attachment 114 is spring loaded through torsion spring 116 off of the deck 14 to be 100 percent retracted upon impact along a wall 118 . Upon contact with the wall 118 , the edge grinder retracts the necessary amount up to 100 percent retraction. The torsion spring allows retraction and recovery to its normal extended position without the need for the operator to stop production to reset anything.
[0071] The vehicle 12 also stores a clean water tank 120 and a recovery tank 122 at the rear end thereof as illustrated in FIG. 3 . The clean water tank may either dispense water, a water cleaning solution mix or a densifier solution used during the grinding process. The solution uses gravity through a distribution bar mounted under the sweeping deck frame. The hopper entrance may be blocked and the sweeping brush becomes a rotary paint brush spreading the applied solution.
[0072] During a sequential grinding pass, the secondary vacuum applied to the hopper is turned off and an independent vacuum attached to the recovery tank is actuated picking up the slurry accumulated at the rear seal 108 .
[0073] In addition an optional small separate pump can deliver water or water mist into or ahead of the grinding heads 36 to enhance the cutting action and extend the life of the cutters 72 . This water delivery system also allows the section of wet grinding. A rear squeegee 111 gathers up any remaining slurry and an appropriate positioned vacuum picks up the gathered slurry. This squeegee 111 eliminates the need for a separate wet grinding machine.
[0074] A power cord handling system is shown in FIGS. 1 , and 10 - 12 . The power cord is used to deliver power to the electric motors 38 of the heads 36 as well as for recharging the electric batteries 31 used to power the motor to drive the vehicle 12 . The power cord 20 extends from a swing arm 18 . The swing arm 18 is pivotably mounted from an upper central tower or arc 124 . The swing arm normally extends rearwardly as shown in FIG. 10 when the vehicle is driven away from the power source 126 and a reel assembly 128 as shown in FIG. 10 . As the vehicle is driven away, the reel rotates as the chord is unrolled therefrom. The reel assembly 128 as shown in FIG. 11 has a take up reel 130 pivotably mounted on a frame 132 that is weighted by weight base 134 that may have about 175 pounds of weight. The reel is spring loaded to be able to take up approximately 150 feet of power cord that contains four #6 flexible wires inside and abrasion resistant sheath of approximately ⅞″ diameter. The weight is used to stabilize the reel assembly 128 against take up force of the spring against the full 150 feet of cord that produces about a 175 pound horizontal pull without sliding or tipping over. The reel assembly has a feed-in cord 136 from a power source such as an outdoor generator.
[0075] As shown in FIG. 12 , as the vehicle 12 moves away from the reel assembly, the swing arm extends rearwardly. As the vehicle 12 turns from the initial direction away from the reel, the swing arm is free to pivot to the side of the vehicle 12 to continue to point toward the reel. The swing arm is allowed to pivot up to approximately 90 degrees to either side as shown when the vehicle 12 is turned moving in a transverse direction. A stop member 136 on top of the arc 124 limits the motion to the 90 degrees such that when the vehicle returns in a direction toward the reel, the swing arm remains at the full left or right position. Furthermore, the reel automatically takes up slack cord as the vehicle 12 moves in a direction toward the reel and allows power cord to be released as the vehicle moves away from the reel. The swing arm 18 has a dimension sufficiently great to extend beyond the left or right side of the vehicle 12 when it is in the full left or right position. In this manner, the power cord is retained off to the side of the vehicle 12 when the vehicle goes in a direction toward the reel. The positioning of the power cord automatically away from the front of the vehicle 12 provides the continuous operation of the vehicle 12 without the need for an operator to stop operating and manually move the power cord off to the side.
[0076] The swing arm may be fitted with a sensor so that if the arm sensor sends a torque above a predetermined amount between the two stops 136 , a warning indicator such as a light or an alarm may be sounded to alert the operator that there is an undesirable condition with the reel, power cord or arm. The sensor may also if desired, be coupled to a deactuation device that safely interrupts the power to the main vehicle until the situation causing the excessive torque is eliminated.
[0077] The reel assembly 128 may also have a wiper 140 positioned to engage and wipe clean the power cord 20 as it is pulled from and reeled back into the reel assembly 128 . This wiper 140 also further reduces the spread of free dust created by the deck 14 .
[0078] Another method for covering floor surfaces is by using shorter runs and instead of making a u-turn which takes time, the operator merely backs up the riding apparatus and slightly turns to a new lane i.e. new floor line. He then moves forward again and back again in a zigzag fashion. When such a zig-zag motion of the ride-on apparatus is done, a modified swing arm as illustrated in FIGS. 13-24 is desired. This swing arm 218 retains the power cord 220 via a hook 238 . There is no usage of the reel 128 in this set up.
[0079] As shown in FIGS. 13 and 20 when the riding apparatus is travelling in a forward direction and away from the from its cord source, the swing arm 218 is usually pulled to the center and rear of the main vehicle body 12 by the drag resistance of the cord 220 . This places the swing arm 218 within the side confines of the vehicle body 12 as clearly shown in FIG. 20 .
[0080] The swing arm 218 has a proximate arm member 222 that is pivotally connected at end 228 to the riding apparatus 10 through a vertical axis. As shown in FIGS. 14-18 , the swing arm 218 also has a distal arm member 224 that is pivotally connected to the proximate arm member through pivotal connection 230 through both arm members 222 and 224 . This pivot connection 230 is also about the vertical axis. The distal arm member has hook 238 mounted at its distal end and a roller 226 also rotatably connected near the distal end for rolling around vertically oriented pivot axis 227 . While the embodiment shown in FIG. 14 shows a single roller, other embodiments may have a plurality of rollers such as the embodiment shown in FIG. 19 that illustrates three rollers. The distal arm has a raised section 240 to provide clearance over the proximate arm 222 . A resilient spring for example in the form of a gas spring member 232 or coil (not shown) is connected to the distal arm at pivot point 234 and to the proximate arm at pivot point 236 . The gas spring 232 normally provides resilient bias to the distal arm member 224 straight on it with respect to the proximate arm member 222 . The spring member 232 provides sufficient resistance to maintain the distal arm member straight against any side forces exerted by dragging of up to 200 feet of power cord along a concrete surface either in the forward direction as shown in FIG. 20 or in as the vehicle 12 moves in the reverse direction as shown in FIG. 22 .
[0081] When a side torque of above a predetermined amount is exerted on the distal arm member 224 , the distal arm can then pivot i.e. yield to the side exerted torque. Such a large side torque may be presented by a building column which may hit the distal arm as the riding apparatus passes. The distal arm member 224 may bend to a position up to a 90 degree as illustrated in FIG. 18 with respect to proximate arm member 222 . A mechanical stop 242 between the two arm members 222 and 224 prevents the distal arm member 224 from flexing more than 90 degrees as shown in FIG. 18 . In this position, the gas spring 232 is almost at its full extension with its inner piston rod 238 extending out therefrom. The gas spring 232 in this position provides for a retraction force so that when the side torque is released, the rod 238 retracts again and pulls the distal arm section 224 back to its straight position as illustrated in FIG. 14 . The connection pivot point 234 of the gas spring is a significant distance form the pivot point 230 of the distal arm member 224 to the proximate arm member 222 to provide for a mechanical advantage of the gas spring and to allow a full 90 degrees of movement of the two arm members 222 and 224 before mechanical contact between the two arm members create a mechanical stop. The geometry also allows the rotation of the distal arm member 224 to go in either direction for a total of 180 degrees of motion with respect to the proximate arm member 222 .
[0082] The zig-zag motion of the riding apparatus 10 and the side bending of the swing arm can be better illustrated with reference to FIGS. 20 to 24 as the vehicle encounters a building support column 250 . When the operator ends the forward run and starts to reverse and turns the vehicle to change lanes and do an overlapping run as shown in FIG. 21 , the drag of the cord 220 riding apparatus 10 then swings the arm 218 sideways. The length of the swing arm 218 is dimensioned to clear either rear corner 240 of the vehicle main body 12 . The operator then straightens out the vehicle still travelling in the reverse direction as shown in FIG. 22 . In this condition, the swing arm 218 extends sideways and protrudes significantly outside the side confines of the vehicle 12 .
[0083] Furthermore, the proximate arm member 222 is dimensioned to be wholly within the side confines of the vehicle 12 . The pivot axis 234 is also within the confines of the vehicle 12 at about a midpoint of the sing arm 218 . The side to side overlap action of the vehicle back and forth runs may vary but it is always less than the width of the vehicle width. It is possible that the overlap allows the sideways extending swing arm 218 , particularly the distal arm member 224 to be within reach of a building support column 250 as shown in FIG. 23 . While the operator is concentrating on making a straight rearward pass as he looks back over his shoulder while steering, he may not pay attention to the reach and position of the swing arm 218 .
[0084] If and when the distal arm member encounters an obstacle, for example a building support column 250 as shown in FIG. 23 , it will yield. The gas spring force is low enough to allow such yielding of the distal arm member when it encounters fixed objects such as building columns. The arm can bend up to 90 degrees to be completely within the confines of the vehicle width as shown in FIG. 24 to allow the vehicle to back up past the building column. Once the building column is cleared, the distal arm member will resiliently pivot back to its extended position as shown in FIG. 97 .
[0085] The roller 226 is preferably a rubber style wheel to further minimize any damage that might occur from contact with walls and columns. Furthermore, the rubber wheels are advantageous when the apparatus 10 is near a room corner and the operator needs to reverse to back up out of the corner. The wheels 226 rolls down the wall preventing the arm from grabbing and digging into the wall, particularly if the wall is made from soft material, for example dry wall. The embodiment shown in FIG. 19 illustrating three rollers 226 even further reduces the impact of collision between the column and the arm since most of the impact will be with the rollers 226 that will tend to roll as opposed to only the distal arm what would otherwise drag against the wall or column.
[0086] Variations and modifications are possible without departing from the scope and spirit of the present invention as defined by the appended claims. | A swing arm for managing a power cord to an electric vehicle has a proximate arm member with a pivotable connection about a vertical axis for connection to the vehicle in proximity to a longitudinal center line of the vehicle. A distal arm member is pivotably connected about a pivot vertical axis to the proximate arm member and resiliently biased to extend straight out with respect to the proximate arm member. The swing arm is dimensioned to extend the distal arm member beyond a side of the vehicle when the swing arm extends laterally with respect to the vehicle. A spring member is connected to the distal arm member for resiliently biasing the distal arm member to extend straight out with respect to the proximate arm member against a side force below a predetermined amount and yieldable to bending of the distal arm member upon exertion of a side force above the predetermined amount. | 1 |
REFERENCE TO RELATED APPLICATION
Reference is hereby made to U.S. patent application Ser. No. 14/580,995, filed Dec. 23, 2014 and entitled Magnetic Stripe Card Reader, the disclosure of which is hereby incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to magnetic stripe card readers generally.
BACKGROUND OF THE INVENTION
Various types of magnetic stripe card readers are known.
SUMMARY OF THE INVENTION
The present invention seeks to provide an improved magnetic stripe card reader.
There is thus provided in accordance with a preferred embodiment of the present invention a magnetic stripe reader including a base element defining a first spring seat, a magnetic module support element arranged for limited pivotable motion relative to the base element and defining a second spring seat, a generally truncated conical spring having a first, relatively large diameter end seated in the first spring seat and a second, relatively small diameter end seated in the second spring seat and a magnetic module fixedly mounted onto the magnetic module support element.
Preferably, the magnetic module support element includes a generally planar portion and a pair of legs disposed generally perpendicularly to generally planar portion, each of the pair of legs defining an elongate slot. Additionally, the base element includes a pair of cylindrical protrusions and a pair of corresponding protrusions and each of the pair of cylindrical protrusions and each of the pair of corresponding protrusions is located in sliding engagement with a corresponding one of the elongate slots associated with one of the pair of legs.
In accordance with a preferred embodiment of the present invention the sliding engagement guides and limits mutual spring loaded displacement between the base element and the magnetic module support element.
In accordance with a preferred embodiment of the present invention the magnetic module support element includes a retaining tab extending in a plane parallel to the plane of generally planar portion and the base element includes a tab engagement surface portion engaging the retaining tab.
In accordance with a preferred embodiment of the present invention the generally truncated conical spring provides displacement of the magnetic module support element relative to the base element when the magnetic stripe reader is engaged by a leading edge of a payment card.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:
FIG. 1 is a simplified illustration of a card reader constructed and operative in accordance with one preferred embodiment of the present invention.
FIGS. 2A and 2B are respective downward-facing and upward-facing pictorial illustrations of a magnetic stripe reader module forming part of the card reader of FIG. 1 ;
FIGS. 2C and 2D are sectional illustration taken along respective lines IIC-IIC and IID-IID in FIG. 2A ;
FIGS. 3A and 3B are respective downward-facing and upward-facing exploded view illustrations of a magnetic stripe reader module forming part of the card reader of FIG. 1 ;
FIGS. 4A and 4B are simplified pictorial illustrations of a base portion of the magnetic stripe reader module of FIGS. 2A-3B , shown in two different orientations;
FIG. 5 is a simplified illustration of a stage in the assembly of the magnetic stripe reader module of FIGS. 2A-4B ;
FIGS. 6A, 6B and 6C are simplified illustrations of the card reader of FIG. 1 in three operative orientations, when a card is not engaged with the card reader, when a card initially engages the magnetic stripe reader module and when a card is engaged in magnetic stripe card reader engagement with the card reader; and
FIG. 7 is a simplified illustration of a card reader constructed and operative in accordance with another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference is now made to FIG. 1 , which is a simplified illustration of a card reader 100 constructed and operative in accordance with one preferred embodiment of the present invention. As seen in FIG. 1 , the card reader 100 comprises a housing, preferably including a top portion 102 and a bottom portion 104 . Disposed within the housing, inter alia, is a main board 106 and a magnetic stripe reader module support base 108 having an aperture 110 communicating with a card swipe slot 112 . A magnetic stripe reader module 114 extends partially through aperture 110 into slot 112 . It is appreciated that throughout the description, the terms “top”, “bottom”, “upper”, “lower” and similar terms refer to the orientations of the various elements as shown in FIG. 1 , with the understanding that the orientation of the card reader 100 and of the magnetic stripe reader module can be any suitable orientation.
Referring now additionally to FIGS. 2A-3B , it is seen that in accordance with a preferred embodiment of the present invention, magnetic stripe reader module 114 preferably comprises a magnetic reader head portion 116 , typically including three parallel mutually spaced magnetic track reading sensors 118 . Magnetic reader head portion 116 is coupled to a flexible flat cable 120 , which operatively connects it to circuitry (not shown) preferably mounted on main board 106 .
Magnetic reader head portion 116 and flexible flat cable 120 are fixedly mounted onto a magnetic head mounting bracket 122 . It is a particular feature of an embodiment of the present invention, that magnetic head mounting bracket 122 is spring mounted onto a base element 124 via a truncated cone spring 126 . A pair of mounting screws 128 serve to attach the magnetic stripe reader module 114 onto the magnetic stripe reader module support base 108 at aperture 110 .
Magnetic head mounting bracket 122 preferably comprises a generally planar portion 130 and a pair of upstanding end portions 131 and 132 integrally formed with planar portion 130 at opposite ends thereof. A pair of legs 134 and 136 are disposed generally perpendicularly to generally planar portion 130 and extend therefrom in a direction opposite to that of upstanding end portions 132 . Legs 134 and 136 are preferably formed with elongate slots respectively designated by reference numerals 138 and 140 and foot portions respectively designated by reference numerals 142 and 144 which lie in a plane parallel to that of planar portion 130 and span respective slots 138 and 140 .
A retaining tab 146 extends in a plane parallel to that of planar portion 130 from a depending portion 148 located at one corner of generally planar portion 130 . A central depending protrusion 150 is preferably formed at a center of an underside surface 152 of generally planar portion 130 . A corresponding recess 154 is preferably formed at the center of an upper surface 156 of generally planar portion 130 . A slot 158 is preferably formed at a junction of planar portion 130 and upstanding end portion 131 and preferably accommodates flexible flat cable 120 , which extends therethrough.
A pair of spot welding locations 160 are preferably located on each of upstanding end portions 131 and 132 and define locations onto which magnetic reader head portion 116 is spot welded thereto.
Reference is now made additionally to FIGS. 4A and 4B , which are simplified pictorial illustrations of base element 124 . As seen in FIGS. 1-4B , base element 124 includes a central portion 170 having a pair of upstanding side portions 172 and 174 , terminating in corresponding mounting flanges 176 and 178 . Mounting flange 176 includes three apertures, here designated by reference numerals 180 , 182 and 184 , while mounting flange 178 includes two apertures, here designated by reference numerals 190 and 191 . Mounting flange 178 extends beyond corresponding side portion 174 and defines a tab engagement surface portion 192 .
Formed on an upper surface 193 of central portion 170 are a pair of partially circular spring seat defining portions, here designated by reference numerals 194 and 196 . Formed in mutually facing orientations on inner facing surfaces of upstanding side portions 172 and 174 are respective generally cylindrical protrusions 198 and 200 and a pair of corresponding protrusions 202 and 204 , each having a partially circular cross-section and extending from corresponding cylindrical protrusions 198 and 200 to upper surface 193 .
Referring now particularly to FIGS. 2C and 2D , it is appreciated that when assembled, the truncated cone spring 126 is seated at its narrow end about protrusion 150 extending downwardly from underside surface 152 of generally planar portion 130 of magnetic head mounting bracket 122 and is seated at its wide end between circular spring seat defining portions 194 and 196 which extend from upper surface 193 of central portion 170 of base element 124 .
Generally cylindrical protrusions 198 & 200 and corresponding protrusions 202 & 204 of base element 124 are preferably located in slidable engagement with respective elongate slots 138 and 140 of respective legs 134 and 136 of magnetic head mounting bracket 122 for guiding and limiting mutual spring loaded displacement therebetween as described hereinbelow with respect to FIGS. 6A-6C .
Reference is now made additionally to FIG. 5 , which is a simplified illustration of a stage in the assembly of the magnetic stripe reader module of FIGS. 2A-4B . It is seen that tab 146 is preferably brought into engagement with tab engagement surface portion 192 of base element 124 just prior to arrangement of slots 138 and 140 of magnetic head mounting bracket 122 into slidable operative engagement with protrusions 198 & 202 and 200 & 204 of base element 124 .
Reference is now made to FIGS. 6A, 6B & 6C , which are simplified illustrations of the card reader of FIGS. 1-5 in three operative orientations, when a card is not engaged with the card reader 100 , when a card initially engages the magnetic stripe reader module 114 and when a card is engaged in magnetic stripe card reader engagement with the card reader 100 , respectively. As seen by comparing FIGS. 6A and 6B , initial insertion of a payment card into slot 112 and engagement of a leading edge of the payment card with the magnetic stripe reader module 114 causes initial skewed displacement of the magnetic stripe reader module 114 against the urging of truncated cone spring 126 , as seen in FIG. 6B .
The displacement of the magnetic stripe reader module 114 and compression of truncated cone spring 126 caused by the engagement of a leading edge of the payment card with the magnetic stripe reader module 114 is seen by a comparison of the distance between a lower surface of central portion 170 of base element 124 and a lower surface of foot portions 144 of leg 136 , as indicated by H 0 in FIG. 6A , and the distance between the lower surface of central portion 170 of base element 124 and the lower surface of foot portions 144 and 142 of legs 136 and 134 , as indicated by H 1 and H 2 on left and right sides in FIG. 6B , respectively. As seen in FIGS. 6A-6B , H 0 and H 1 are equal, since the left side of the reader, as seen in FIG. 6B , has not been displaced downwardly, while H 2 is less than H 0 , since the right side of the reader, as seen in FIG. 6 B, has been displaced downwardly by the engagement of a leading edge of the payment card with the magnetic stripe reader module 114 .
Once the leading edge of the payment card passes the highest portion of the magnetic stripe reader module 114 , as seen in FIG. 6C , the magnetic stripe reader module 114 is further displaced against the urging of truncated cone spring 126 and is no longer skewed but is displaced downward with respect to slot 112 , as compared with its orientation in the absence of card engagement, as seen in FIG. 6A .
The displacement of the magnetic stripe reader module 114 and compression of truncated cone spring 126 caused by the leading edge of the payment card passing the highest portion of the magnetic stripe reader module 114 is seen by a comparison of the distance between a lower surface of central portion 170 of base element 124 and a lower surface of foot portions 144 of leg 136 , as indicated by H 1 in FIG. 6B , and the distance between the lower surface of central portion 170 of base element 124 and the lower surface of foot portion 144 of leg 136 , as indicated by H 3 in FIG. 6C . As seen in FIGS. 6B-6C , H 1 is greater than H 3 and H 2 equals H 3 , since the left side of the reader, as seen in FIG. 6C , has been displaced downwardly by the engagement of the payment card with the magnetic stripe reader module 114 to the same extent as the right side of the reader was previously displaced.
In a preferred embodiment of the present invention, spring 126 exerts a force of approximately 1.0 Newtons in the absence of a card in slot 112 . During card swipe, when a magnetic stripe card is in operative engagement with the magnetic stripe reader module 114 , the force exerted by spring 126 increases to about 1.6 Newtons, due to compression of springs 126 .
Reference is now made to FIG. 7 , which is a simplified illustration of a card reader 300 constructed and operative in accordance with another preferred embodiment of the present invention. As distinguished from card reader 100 described hereinabove with reference to FIGS. 1-6C , card reader 300 is characterized in that it contains a sideways mounted magnetic stripe reader module 314 , which may in all relevant respects be identical to magnetic stripe reader module 114 of FIGS. 1-6C .
It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly claimed and includes both combinations and subcombinations of features described and shown hereinabove as well as modifications thereof which are not in the prior art. | A magnetic stripe reader including a base element defining a first spring seat, a magnetic module support element arranged for limited pivotable motion relative to the base element and defining a second spring seat, a generally truncated conical spring having a first, relatively large diameter end seated in the first spring seat and a second, relatively small diameter end seated in the second spring seat and a magnetic module fixedly mounted onto the magnetic module support element. | 6 |
FIELD
The invention is based on a roller storage system for storing sheet-type objects, especially bank notes, between the winding layers of two sheet-type films which are spooled back and forth between a first and a second film drum, on the one hand, and a winding drum, on the other hand.
BACKGROUND
Roller storage systems are used, in addition to cassette storage systems, in automated teller machines, cashbox systems and other money processing systems, such as, for example, automatic cash desk vaults and money recycling systems. Roller storage systems allow bank notes to be deposited and dispensed in a quick and simple manner. When deposits are made into the roller storage system or the roller storage system is filled, the bank notes are successively wound onto the winding drum between the winding layers of one or two films. In a first variant of a roller storage system having just one storage strip, the bank notes are held between the winding layers of a strip-shaped film serving as a storage strip. In a second variant, in addition to the first film, a second strip-shaped film, serving as a cover strip, is provided. For the first and second film, a first and a second film drum are arranged spatially separate from each other in the roller storage system. The two films are brought together via a respective deviating roller. At the deviating rollers, the sheet-type objects, when deposited, are introduced between the films and, when dispensed, are withdrawn from the films. Leaving the deviating rollers, the two films are fed, lying one upon the other, to the winding drum. The sheet-type objects are thus held between the first and the second film. The present roller storage system is here constituted by a roller storage system of the second variant.
For the dispensing of the sheet-type objects, the films are wound off from the winding drum and wound onto the film drums. In this operation, the sheet-type objects are released from the winding layers and can be successively withdrawn. The dispensing of the sheet-type objects is thus realized according to the “last in”, “first out” principle.
Since the depositing and dispensing of the sheet-type objects is realized automatically and at high speed, it is of crucial importance that the sheet-type objects are guided and held by the films in a reliable manner. If a sheet-type object becomes wholly or partially detached from the films during transport, then this leads to a jam in the roller storage system, with the result that the apparatus has then to be opened manually and the cause of the jam removed. For this, operation of depositing or dispensing the sheet-type elements must be interrupted.
SUMMARY
The object of the present invention is to provide a roller storage system which allows a reliable guidance of the sheet-type objects between the films, so that the risk of unwanted detachment of objects from the film guide is minimized.
The roller storage system according to the invention and having the features of claim 1 has the advantage over roller storage systems known from the prior art that the first deviating roller assigned to the first film and the second deviating roller assigned to the second film are mutually offset in the direction of transport. The two films are arranged one behind the other with respect to the film transport direction prevailing between the deviating rollers and the winding roller. This means that, both in the depositing and in the dispensing operation, a sheet-type object passes first the one and then the other deviating roller with its, in the direction of transport, front edge. The path length and the period for which the edge of an object is at least indirectly in contact with one of the two deviating rollers is dependent on the distance over which the first and second film are in direct or indirect contact with the deviating roller. In the portion between the winding drum and the deviating roller arranged closest to the winding drum, the first and second film lie adjacent to each other. An object is indirectly in contact with a deviating roller when it is separated from the deviating roller only by one of the two films and the other film is pressing it against the deviating roller. A film is indirectly in contact with a deviating roller when it is separated from the deviating roller only by the other film and, where appropriate, an object.
The two deviating rollers are arranged offset in such a way that the two films, having passed the deviating roller situated closest to the winding drum, lie closely adjacent to each other. This is achieved either by a minimal distance between the two offset deviating rollers, or by a change of direction of the film travel between the first and second deviating roller, on the one hand, and the deviating rollers and the winding drum, on the other hand. In the second case, the distance between the two deviating rollers can be greater than the minimum distance in the first case. The maximum distance between the two deviating rollers is limited by the overall size of the roller storage system and the length of the sheet-type objects. Advantageously, the distance between the deviating rollers should not be greater than the length of the sheet-type objects, measured in the direction of transport.
The sheet-type objects are taken up, during transport from the winding drum to the deviating rollers, first by one and then by the other deviating roller. The path over which a guided and reliable transport of the objects is realized is greater with an offset arrangement of the deviating rollers than if the deviating rollers are arranged at the same position in the direction of transport. This allows a reliable transport of the objects between the deviating rollers and the winding drum. An unwanted detachment of the objects from the films can thereby be prevented.
Since the two films between the two deviating rollers and the winding drum lie adjacent to each other, a force is applied to the objects arranged between the films insofar as at least one of the two films is in contact with one of the two deviating rollers. The film facing away from this deviating roller is drawn, due to the film guide, likewise in the direction of the deviating roller. The object arranged between the films is clamped reliably in place.
The deviating rollers, in addition to their above-described positioning, can also be arranged offset with respect to the document feed-in and the document feed-out. This depends on the direction of the document feed-in and of the document feed-out. This direction is predefined, in the depositing operation, by a document guide arranged in front of the deviating rollers and, in the dispensing operation, by a document guide arranged after the deviating rollers. If the direction is consistent with the perpendicular bisectors of the connecting paths of the axes of the two deviating rollers, then the sheet-type objects, when documents are fed in, are simultaneously taken up by both deviating rollers. Similarly, the objects, when documents are fed out, are simultaneously released by both deviating rollers. In this case, no offset is present. If, however, the direction of the document guidance differs from the perpendicular bisectors of the connecting paths of the axes of the two deviating rollers, then the deviating rollers are offset also relative to the document feed-in and/or the document feed-out. In this case, the sheet-type objects, when documents are fed in, are taken up first by one and then by the other deviating roller. Correspondingly, the sheet-type objects, when documents are fed out, are released first by one and then by the other deviating roller.
When the sheet-type objects are deposited and dispensed in the horizontal direction, the offset arrangement of the first and second deviating roller is obtained by virtue of the position of the axis of the first deviating roller lying outside a vertical plane running through the axis of the second deviating roller. If the depositing and dispensing of the sheet-type objects takes place in the vertical direction, then an offset arrangement of the first and second deviating roller is obtained by virtue of the position of the axis of the first deviating roller lying outside a horizontal plane running through the axis of the second deviating roller.
Advantageously, the two deviating rollers, despite the offset, have a minimum distance apart to ensure that the two films are brought close together by the deviating rollers and the sheet-type objects are held between the films. The offset of the axis of the second deviating roller relative to the first deviating roller is therefore preferably realized on a circle, the center point of which forms the axis of the first deviating roller. The radius of this circle corresponds to the sum of the radii of the two deviating rollers and the minimum distance apart. This is predefined, for example, by the sum of the thicknesses of the first and second film and double the thickness of the sheet-type objects. To this, a tolerance range of 20% can be added.
According to an advantageous embodiment of the invention, the offset between the first and second deviating roller is less than the length of the sheet-type objects, measured in the direction of transport. The distance apart of the two deviating rollers is chosen sufficiently small in the direction of transport of the films that the sheet-like objects, over a certain distance of the transport path, are simultaneously taken up by both deviating rollers. If the sheet-type objects are supplied and withdrawn in the horizontal direction, this means that the distance between the axis of the first deviating roller and the vertical plane running through the axis of the second deviating roller is less than the length of the sheet-type objects, measured in the direction of transport. That end of the sheet-type object which is situated at the rear in the direction of transport is thus only released by one deviating roller once the front-situated end of the sheet-type object in the direction of transport is taken up by the other deviating roller. This leads to a reliable document guidance by two deviating rollers over the distance between the two deviating rollers, and by at least one deviating roller over a correspondingly greater distance.
According to one advantageous embodiment of the invention, the two deviating rollers have the same diameter. The offset between the first deviating roller and the second deviating roller here amounts to at least 25% of the diameter of the deviating rollers. From this value, the offset between the two deviating rollers is large enough for the above-stated positive effects to make themselves felt.
According to one advantageous embodiment of the invention, the two deviating rollers have the same diameter. The offset between the first deviating roller and the second deviating roller here amounts to no more than 40% of the diameter of the deviating rollers. In principle, the offset can also be further enlarged. The document feed-in in the horizontal direction, when the objects are introduced between the two deviating rollers, is then however made more difficult, and the overall size of the roller storage system is possibly over-enlarged.
According to a further advantageous embodiment of the invention, at least a first back-up roller is arranged between the two deviating rollers and the winding drum. The guidance of the films, and of the objects between the films, is thereby further improved. Advantageously, the back-up roller is arranged in such a way relative to the two films that the films undergo a change of direction as a result of the back-up roller. The first plane, which is predefined by the course of the films between the two deviating rollers and the back-up roller, and the second plane, which is predefined by the course of the film between the back-up roller and the winding drum, intersect at an angle different than 0° and 180°. Upon the change of direction, the two films are pressed against the back-up roller and the objects are clamped reliably in place between the films.
According to a further advantageous embodiment of the invention, a second back-up roller is arranged between the first back-up roller and the winding drum such that it is offset relative to the first back-up roller in the direction of transport of the films. As a result of the offset arrangement of a second back-up roller, the objects arranged between the films are subjected to an additional force which fixes the objects in their position relative to the films and thus prevents detachment of the objects from the films. The objects cannot slide out between the films. This increases the reliability of the transport. Furthermore, the offset arrangement of two back-up rollers means that the front edge of a sheet-type object first passes one and, with time stagger, the other back-up roller. In this way, the distance over which at least one of the two back-up rollers applies a force to the sheet-type objects is enlarged. The sheet-type objects are thus, between the two deviating rollers and the winding drum, in continuous contact with a deviating roller or a back-up roller. The partial or complete detachment of the sheet-type objects from the films, resulting in a change of position of the objects relative to the films in the portion between the deviating roller and the winding roller, is thereby precluded.
In the case of a horizontal document feed-in, the offset of the two back-up rollers results in the distance between the axis of the first back-up roller and a horizontal plane running through the axis of the second back-up roller being less than the sum of the radii of the first and second back-up roller. The offset of the first back-up roller relative to the nearest placed deviating roller results in the distance between the axis of the first back-up roller and a horizontal plane running through the axis of the second deviating roller being less than the sum of the radii of the second deviating roller and the first back-up roller.
According to a further advantageous embodiment of the invention, the back-up rollers have a smaller diameter than the deviating rollers. The back-up rollers can thereby be arranged particularly close to the winding drum.
A reliable guidance of the objects up to the winding drum and a small overall size of the roller storage system is hereby made possible.
According to a further advantageous embodiment of the invention, on the axis of the first and/or of the second deviating roller, at an axial distance to the deviating roller, at least one disk is arranged, the radius of which is greater than the radius of the deviating roller. During transport, the disk applies a force to the sheet-type object and ensures deflection of a region of the sheet-type object. If both deviating rollers are equipped with such a disk on different sides, then the two disks do not get in the way of each other. During its transport through the two deviating rollers, the sheet-type object acquires a wave shape. The deformation of the sheet-type object has a positive effect upon the reliability of the transport. In a preferred manner, the diameter of a disk is maximally 40% greater than the diameter of the adjacent deviating roller. Particular preference is for a diameter which is between 1 and 10% greater than the diameter of the deviating roller.
According to a further advantageous embodiment of the invention, the disk has a soft, rubbery surface. As a result of this surface, the friction between the sheet-type object and the disk is intensified and the take-up of the object is optimized. Despite the high friction coefficient, the material of the surface must have a certain hardness so that it is not or only slightly deformed in the guidance of the sheet-type objects. The disk can be constituted, for example, by a timing disk for determining the rotation speed of the deviating roller. This is equipped with openings in the radial direction.
According to a further advantageous embodiment of the invention, the axes of the first and second film drum, of the winding drum and of the first deviating roller are arranged fixedly on a housing. The axis of the second deviating roller is arranged fixedly on a deviating roller housing part, which is held on the housing rotatably about an axis. This deviating roller housing part has the advantage that the second deviating roller can be moved apart from the first deviating roller in order to remedy a jam in the roller storage system. In this way, folded sheet-type objects, which obstruct the transport in the roller storage system, can be quickly and easily removed. On the housing, an end stop can be provided to limit the included angle between the first and the second deviating roller. The housing or the deviating roller housing part can be equipped with a locking lever, which locks the deviating roller housing part in the closed setting. The locking lever encompasses, in the closed setting, a locking bolt. The imaginary or real axis, about which the deviating roller housing part is rotatable, is advantageously located between the deviating rollers and the winding drum in order to be able to reach as far as possible into the region between the deviating rollers and the winding drum when the deviating roller housing part is open. Insofar as the roller storage system is equipped with back-up rollers in addition to the deviating rollers, in an advantageous embodiment of the invention one of the two back-up rollers is disposed fixedly on the housing and the other back-up roller on the deviating roller housing part.
According to a further advantageous embodiment of the invention, the housing and/or the deviating roller housing part is/are equipped with guide elements, which are arranged in a funnel shape. These are preferably located between the back-up rollers and the side wall of the housing. They result in a folded-over region of a sheet-type object being straightened out during transport between the deviating rollers and the winding drum. A jam in the roller storage system which has been triggered by folded-over regions can thereby be prevented and a folded object can be converted into an unfolded state.
According to a further advantageous embodiment of the invention, the roller storage system is equipped with a U-shaped light guide. Both ends of the U-shaped light guide extend up to the axis of one of the two deviating rollers.
They are oriented, for the coupling-in and coupling-out of light, in the direction of the respectively other deviating roller. Close to the axis of the other deviating roller, opposite to the ends of the U-shaped light guide, a light source and a light-sensitive sensor are arranged. The position of the U-shaped light guide should here be chosen such that the two ends of the U-shaped light guide are covered neither by the first, nor by the second film. A covering of one or both ends of the U-shaped light guide takes place only insofar as a sheet-type object is being led through between the two deviating rollers. If the light-sensitive sensor receives no light from the light source, then it is concluded that a sheet-type object is present between the two deviating rollers. Only once the sheet-type object has fully passed the two deviating rollers are both ends of the U-shaped light guide released and the sensor again receives light from the light source. In this way, the sheet-type objects wound onto the winding drum or wound off from the winding drum can be counted when passing the deviating rollers. The proximity of the ends of the U-shaped light guide to the axes of the two deviating rollers guarantees a small overall size of the roller storage system, as well as the detection of the sheet-type objects guided past the deviating roller.
According to a further advantageous embodiment of the invention, the roller storage system is equipped with two first films serving as storage strips and with two second films serving as cover strips. For this purpose, two first film drums and two second film drums are disposed on the roller storage system. The two first films can be arranged side by side on a common axis. The equivalent applies to the two second film drums. Each film receives a corresponding guide, so that two first deviating rollers, two second deviating rollers, and a corresponding number of back-up rollers are provided. The greater number of films has the advantage that the sheet-type objects are held not just in one region, but in two regions, by the mutually adjacent films, and that each of the films, as well as the deviating rollers and back-up rollers, can have a smaller width than in the case of just one film pair.
Further advantages and advantageous embodiments of the invention can be derived from the following description, the drawing and the claims.
DRAWINGS
An illustrative embodiment of the invention is represented in the drawing, wherein:
FIG. 1 shows a schematic representation of a roller storage system in side view,
FIG. 2 shows a view of the deviating rollers and of the back-up rollers of the roller storage system according to FIG. 1 in a view from the front,
FIG. 3 shows a perspective view of the roller storage system according to FIG. 1 , with closed deviating roller housing part,
FIG. 4 shows a roller storage system according to FIG. 3 with open deviating roller housing part,
FIG. 5 shows a deviating roller housing part in a view from below,
FIG. 6 shows a deviating roller housing part in side view, with open locking lever,
FIG. 7 shows a deviating roller housing part with closed locking lever,
FIG. 8 shows part of the roller storage system in perspective view,
FIG. 9 shows part of the roller storage system in perspective view,
FIG. 10 shows a deviating roller housing part in perspective view with funnel-shaped document guide,
FIG. 11 shows a detail from FIG. 5 , deviating rollers with disks and U-shaped light guide.
DETAILED DESCRIPTION
In FIG. 1 , a roller storage system is shown in simplified representation in a side view, with open housing. In the middle is located a winding drum 1 having a winding core 2 . The outer circle around the winding core 2 indicates the periphery of the winding drum 1 in the filled state. To the left of the winding drum 1 , two first film drums 3 and two second film drums 4 are represented. The two first film drums 3 are arranged axially side by side on the axis 5 . The two second film drums 4 are arranged axially side by side on the axis 6 . Since the direction of view in FIG. 1 corresponds to the orientation of the axes 5 and 6 , in FIG. 1 only that film drum which is facing the viewer is visible. The two first film drums 3 are fixedly connected to the axis 5 , which is rotatably driven by a motor (not represented in the drawing). The equivalent applies to the two second film drums 4 and the axis 6 . Onto each of the two first film drums 3 is wound a first film 7 , which is guided, via two guide rollers 8 , a first deviating roller 9 and a back-up roller 10 , to the winding drum 1 . Exactly like the two first film drums 3 , the two first films 7 , the guide rollers 8 , the two deviating rollers 9 and the two back-up rollers 10 are arranged side by side, so that in FIG. 1 only one of the said rollers is in each case visible to the viewer. Onto the two second film drums 4 there is respectively wound a second film 11 , which second films are fed, via the guide rollers 12 , a second deviating roller 13 and a second back-up roller 14 , to the winding drum 1 . The axes of the winding drum 1 , of the first film drums 3 , of the second film drums 4 , of the guide rollers 8 and 12 , of the deviating rollers 9 and 13 , and of the back-up rollers 10 and 14 run parallel. At the two deviating rollers 9 and 13 , the first films 7 and the second films 11 are brought together, so that they lie closely adjacent to each other. In the portion between the two deviating rollers 9 and 13 and the winding drum 1 , a first film 7 lies respectively on a second film 11 . The document feed-in of sheet-type objects (not represented in FIG. 1 ) takes place in the horizontal direction according to the arrow marked with the numeral 15 in FIG. 1 . An apparatus serving to guide the document to the document feed-in is not represented in the drawing. The sheet-type objects arriving at the two deviating rollers 9 and 13 are first taken up by the first film, which is guided via the first deviating roller 9 , and then fed to the second film, which is guided around the second deviating roller 13 . This time-staggered contacting of the first and second deviating roller 9 and 13 is realized on the basis of an offset between the two deviating rollers. In FIG. 1 , this offset is indicated by two parallel lines emanating from the axes of the deviating rollers 9 and 13 . From the second deviating roller 13 , the first and second films 7 and 11 are pressed one against the other and the sheet-type objects arranged between them are held. Due to the force which the two deviating rollers 9 and 13 , as well as the two back-up rollers 10 and 14 , apply to the first and second film, and thus to the sheet-type objects between the films, as well as the friction existing between the sheet-shaped objects and the films, the position of the sheet-shaped objects relative to the films is maintained from the two deviating rollers 9 and 13 up to the winding drum 1 . As soon as the objects are on the winding drum, their position, given sufficient tensioning of the films, no longer changes. Between the two deviating rollers 9 and 13 and the winding drum 1 , the two films 7 and 11 , as well as the sheet-shaped objects arranged between them, undergo several changes of direction by virtue of the two back-up rollers 10 and 14 . Due to these changes of direction, additional forces are applied to the two films and to the sheet-shaped objects arranged between them. The distance between the two deviating rollers 9 and 13 , the first back-up roller 10 , the second back-up roller 14 and the winding drum 1 is chosen such that even the smallest sheet-type object, between the first deviating roller 9 and the winding drum 1 , is always in contact with at least one deviating roller or at least one back-up roller. The films are not only guided tangentially past the two deviating rollers 9 and 13 , as well as the two deviating rollers 10 and 14 , but are diverted into another direction, whereby the contact between film and deviating roller, as well as between film and back-up roller, is made over a larger film portion and the applied force is increased.
The document feed-out is realized by the two films 7 and 11 being wound, via the two back-up rollers 10 and 14 , the two deviating rollers 9 and 13 and the guide rollers 8 and 12 , onto the film drums 3 and 4 . The sheet-type objects are dispensed between the two deviating rollers 9 and 13 in the horizontal direction oppositely to the arrow 15 .
FIG. 2 shows the two first deviating rollers 9 and the two second deviating rollers 13 in a view from the front. The direction of view here corresponds to the document feed-in marked with an arrow in FIG. 1 . Each of the deviating rollers 9 and 13 is mounted rotatably about an axis 16 and 17 . At an axial distance to the two first deviating rollers 9 , a disk 18 is respectively arranged, on the side facing away from the respectively other first deviating roller, rotatably on the axis 16 . A spacer (not visible in the drawing) here ensures that the distance between the first deviating rollers 9 and the disks 18 remains constant. Corresponding disks 19 are disposed on the axes 17 of the second deviating rollers 13 . Unlike the disks 18 , the disks 19 are positioned between the two second deviating rollers. The diameter of the two disks 18 and 19 is greater than the diameter of the first and second deviating rollers 9 and 13 . This results in a sheet-type object 20 , in its transport between the first and second deviating rollers 9 and 13 , undergoing a sinuous or wavy deformation as a result of the disks 18 and 19 . This deflection of the sheet-type object 20 is represented in FIG. 2 . The sheet-shaped object is curved by the disks downward in the middle between the deviating rollers 9 and 13 and upward at the sides.
FIGS. 3 and 4 show the roller storage system with housing 21 in perspective view. The document feed-in takes place in the direction of the arrow marked with the reference numeral 15 in FIG. 3 . The first deviating rollers 9 are visible in the representation according to FIGS. 3 and 4 . On a deviating roller housing part 22 arranged rotatably on the housing 1 , the second deviating rollers 13 and the second back-up rollers 14 are disposed. The axes of all other elements of the roller storage system are arranged fixedly in the housing 1 . The deviating roller housing part 22 is rotatable about the axis 23 . Two recesses 24 in the side walls 25 of the housing form a stop for a pin 26 on the deviating roller housing part and thus delimit the included angle of the deviating roller housing part 22 . By opening the deviating roller housing part 22 , it is possible to reach into the region of the first and second deviating rollers 9 and 13 and of the first and second back-up rollers 10 and 14 . In this way, jammed documents are able to be removed from the region.
FIGS. 5 , 6 and 7 show the deviating roller housing part 22 in various views. Engaging in the receiving fixtures 27 is an axle journal (not visible in the drawing) disposed on the side walls 25 of the housing 21 . A locking lever 28 disposed on the side of the deviating roller housing part 22 encompasses, in the closed setting, a locking bolt 29 on the side walls 25 of the housing 21 . The locking is supported by the compression springs 30 . The locking lever 28 is visible in FIG. 4 .
FIGS. 8 and 9 show a detail from the roller storage system, comprising the two first deviating rollers 9 , the two first back-up rollers 10 and the two disks 18 . These parts are surrounded by a document guide 31 having guide elements, which, on the sides and in the middle between the back-up rollers 10 , are of funnel-shaped configuration. For this purpose, the document guide is provided both laterally and in the middle with guide elements 32 in the form of indents, which are rounded in the direction of transport. A sheet-type object which is fed onto these indents and whose corners are folded over, or which is lacerated in the middle, is subjected through the edges to a force which leads to the straightening-out of the folded-over corners and to the orientation thereof in the plane of the other sheet-type object.
In FIG. 10 , the deviating roller housing part 22 equipped with a corresponding document guide 33 is represented. In the deviating roller housing part 22 also, the document guide 33 has guide elements 34 in the form of indents in the middle between the back-up rollers 14 , as well as to the side of the back-up rollers.
These take the form of beveled regions with round edges, which serve the same purpose as described above. In the closed setting of the deviating roller housing part, the guide elements 32 and 34 of the document guides 31 and 33 are arranged opposite each other and form a three-dimensional funnel for the sheet-type objects. Both upwardly and downwardly folded-over regions of the sheet-type objects are thus straightened.
In FIG. 11 , the deviating roller housing part 22 is represented without the document guide 33 . In this representation can be seen the U-shaped light guide 35 , which encompasses the two disks 19 and extends with its two ends up to the axis 17 of the second deviating roller 13 . The document guide 33 has two rectangular recesses 36 for the two ends of the U-shaped light guide 35 . As a result of these two recesses 36 , light is coupled into and coupled out from the ends of the light guide. For this purpose, in the document guide 31 , which in the closed setting lies opposite the document guide 32 , corresponding recesses 37 are arranged, which are visible in FIGS. 8 and 9 . Behind these recesses 37 , a light source and a light-sensitive sensor are arranged. These two parts are not represented in the drawing. Via the light source, light is coupled in at one end of the light guide and coupled out at the other end, to allow detection by means of a light-sensitive sensor. The ray path between the light source and the sensor is interrupted if at least one of the two recesses 36 and 37 is covered by a sheet-shaped object transported between the deviating rollers. Based on the interruption of the ray path, a sheet-shaped object is thus detected between the deviating rollers 9 and 13 . By virtue of the light guide, both the light source and the sensor can be accommodated in the fixed housing. They do not therefore form a constituent part of the rotatable deviating roller housing part. The wiring is thereby facilitated. As a result of the U-shaped light guide, a light-guidance close to the axes 19 and the two deviating rollers 13 is enabled, despite the two disks 19 . This happens in such a tight space that the overall size of the deviating roller housing part is not enlarged by the U-shaped light guide 35 .
All features can be fundamental to the invention both individually and in any chosen combination with one another. | A roller storage system for storing sheet-type objects, in particular bank notes, is proposed, comprising a first film drum ( 3 ), which can be rotatably driven by a motor, with a first strip-shaped film ( 7 ) as a storage strip, comprising a second film drum ( 4 ), which can be rotatably driven by a motor, with a second strip-shaped film ( 11 ) as a cover strip, and comprising a winding drum ( 1 ), which can be rotatably driven by a motor. The films ( 7, 11 ), for the reception of the sheet-type objects ( 20 ), can be wound from the two film drums ( 3, 4 ) onto the winding drum ( 1 ) and, for the dispensing of the sheet-type objects ( 20 ), can be wound from the winding drum ( 1 ) onto the two film drums ( 3, 4 ). A first deviating roller ( 9 ) between the first film drum ( 3 ) and the winding drum ( 1 ) serves for the diversion of the first film ( 7 ). A second deviating roller ( 13 ) between the second film drum ( 4 ) and the winding drum ( 1 ) serves for the diversion of the second film ( 11 ). The second deviating roller ( 13 ) is here arranged offset relative to the first deviating roller ( 9 ) in the direction of transport of the films ( 7, 11 ). | 1 |
FIELD OF THE INVENTION
The present invention relates to an ion optics set for an ion beam source, particularly ion beam sources for space propulsion, such as ion thrusters.
BACKGROUND OF THE INVENTION
Space propulsion, surface cleaning, ion implantation, and high energy accelerators use ion beam sources. These beam sources typically use two or three closely spaced multiple-aperture electrodes to extract ions from a source and eject them in a collimated beam. These electrodes are called "grids" because they have a large number of small holes. Typically, tile grids are made from molybdenum. A series of grids constitute an electrostatic ion accelerator and focusing system commonly referred to as the "ion optics."
Ion beam sources designed for spacecraft propulsion, that is, ion thrusters, should have long lifetimes (10,000 hours or more), be efficient, and be lightweight. These factors can be important in other applications as well, but they are not as critical to successful use as they are for ion thrusters. Ion thrusters have been successfully tested in space, and show promise for significant savings in propellant because of their high specific impulse (an order of magnitude higher than that of chemical rocket engines). They have yet to achieve any significant space use, however, due in part to lifetime limitations imposed by grid erosion and to performance constraints imposed by thermal-mechanical design considerations resulting from the use of metallic grids.
A typical configuration of an ion thruster is known as an electron bombardment ion thruster. In an electron bombardment ion thruster, electrons produced by a cathode strike neutral gas atoms introduced through a propellant feed line. The electrons ionize the gas propellant and produce a diffuse plasma. In other types of ion thrusters, known as "radio frequency ion thrusters," the propellant is ionized electromagnetically by an external coil, and there is no cathode. In both cases, an anode associated with the plasma raises its positive potential. To maintain the positive potential of the anode, a power supply pumps some of the electrons that the anode collects from the plasma down to ground potential. These electrons are ejected into space by a neutralizer to neutralize the ion beam. Magnets act to inhibit electrons and ions from leaving the plasma Ions drift toward the ion optics, and enter the holes in a screen grid. A voltage difference between the screen grid and an accelerator grid accelerates the ions, thereby creating thrust. The screen grid is at the plasma potential, and the accelerator grid is held at a negative potential to prevent downstream electrons from entering the thruster. Optionally, the optics can include a decelerator grid located slightly downstream of the accelerator grid and held at ground potential or at a lesser negative potential than the accelerator grid to improve beam focusing and reduce ion impingement on the negative accelerator grid.
A primary life limiting mechanism in ion thrusters is erosion of the ion optics (i.e., the grids) from ions impacting the grid material and sputtering it away. In ion thrusters, slow moving ions are produced within and downstream of the ion optics by a charge exchange (i.e., electron hopping) from neutral propellant atoms to fast moving ions that pass close by. These "charge exchange" ions are attracted to the accelerator grid and strike it at high energy, gradually eroding it away. The screen grid also experiences some erosion, mostly on the upstream side. This erosion of both the screen grid and accelerator grid eventually produces additional holes in the grids, causing them to cease functioning properly. Grid erosion is the primary life-limiting mechanism for ion optics.
A principal factor affecting both the efficiency and the weight of ion thrusters is how closely and precisely the grids can be positioned while maintaining relative uniformity in the grid-to-grid spacing under conditions conducive to significant thermal distortion. In the past, this factor has limited the maximum practical diameter of ion thrusters, which severely constrains taking advantage of scale effects that theoretically would improve efficiency, thrust-to-weight ratio, and reliability.
Molybdenum ion thruster grids are precisely hydroformed into matching convex shapes. The apertures are chemically etched. The convex shapes provide a predictable direction for the deformation that occurs due to thermal expansion when a thruster heats in operation. Changes in the actual spacing and the uniformity of spacing over the grid surfaces between the molybdenum grids is unpredictable and uncontrollable. The thermal expansion distribution is complex.
The changes in spacing that occur adversely effect performance. Although techniques have been developed to compensate for such changes, the unpredictable and nonuniform nature of the changes prevents complete compensation.
In ion beam sources used for terrestrial applications, today's grids are sometimes made of graphite, which expands much less than molybdenum when heated. Graphite is, however, relatively flexible and fragile and is not suitable for beam sources larger than about 15-20 cm in diameter, or for ion thruster grids, which are subject to severe vibration during launch from Earth.
It is desirable to have a screen grid and accelerator grid that have lifetimes of 10,000 to 20,000 hours for use in a variety of space propulsion applications. Such grids should also have an increased efficiency and should be lightweight for space applications. Additionally, the screen grids should allow for the construction of an ion optics set wherein the magnitude and uniformity of the spacing between the grids can be precisely predicted and maintained over the temperature range and pattern of differential surface heating the grids experience in use.
SUMMARY OF THE INVENTION
The present invention relates to an ion thruster having improved performance arising from using screen grids and accelerator grids made of carbon-carbon composite material. Carbon-carbon grids are lightweight and resistant to erosion. Carbon-carbon composite material can be fabricated such that its coefficient of thermal expansion is essentially zero. Heat effects on the carbon-carbon grids, therefore, are negligible. The grids maintain their relative spacing across the range of operating temperatures. They maintain their shape against differential surface temperatures. The gradient across the grids has no significant affect. In another aspect, the present invention relates to a process for producing grids made of carbon-carbon composite material.
In one aspect, the present invention is a grid element in an ion optics set for use in an ion beam source. The grid element includes a body having a plurality of apertures. The body is a carbon-carbon composite comprising carbon fibers embedded in a carbon matrix. This grid element can either be a screen grid, accelerator grid, or a decelerator grid.
In another aspect, the present invention is a process for manufacturing a carbon-carbon composite grid element for an ion beam source. The process includes the steps of positioning a plurality of carbon fibers in a crossed or woven array. This array of carbon fibers is then embedded in a carbon matrix. Apertures can be provided in the array during the positioning of the fibers, or the apertures may be cut after the fibers are embedded in the matrix.
In yet another aspect, the present invention is an ion optics set that includes a screen grid and an accelerator grid that each include a plurality of apertures and a body comprised of a composite of carbon fibers and a carbon matrix. Due to the virtually nonexistent thermal expansion of the grids formed in accordance with the present invention, the ion optics set can include a narrow gap which will remain substantially constant during operation.
It is important that the apertures between grids be precisely aligned and that they remain aligned. Otherwise, accelerated ions are directed into the next grid or are ejected at an angle to the desired axial direction. Carbon-carbon grids maintain this precise alignment of holes from grid to grid.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will be better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings.
FIG. 1 is a schematic diagram of an ion thruster constructed in accordance with this invention;
FIG. 2 is an illustration of ion optics included in the thruster of FIG. 1 and having grids and mounting rings constructed in accordance with this invention;
FIG. 3 is a plan view from the top of a screen grid formed in accordance with the present invention;
FIG. 4 is a plan view of the top of a second embodiment of a screen grid formed in accordance with the present invention;
FIG. 5 is a plan view of the top of a third embodiment of a screen grid formed in accordance with the present invention;
FIG. 6 is a plan view of the top of one embodiment of an accelerator grid formed in accordance with the present invention;
FIG. 7 is an enlarged plan view of a portion of the top of the screen grid of FIG. 1;
FIG. 8 is an enlarged plan view of a portion of the top of a screen grid formed in accordance with the present invention;
FIG. 9 is an enlarged plan view of a portion of the top of the screen grid of FIG. 5;
FIG. 10 is an elevational view of a cross section of an aperture in the screen grid of FIG. 2;
FIG. 11 is an elevational view of a cross section of an aperture in the accelerator grid of FIG. 6;
FIG. 12 is a graph of accelerator grid impingement current (J a ) as a function of beam voltage (V b ) for an ion optics set formed in accordance with the present invention;
FIG. 13 is a graph of accelerator grid voltage (V a ) as a function of beam current (J b ) for an ion optics set formed in accordance with the present invention; and
FIG. 14 is a graph of the ratio of accelerator grid impingement current (J a ) to beam current (J b ) as a function of net-to-total voltage ratio (R=V b /V t ) for an ion optics set formed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is described in the context of an ion thruster 1, shown schematically in FIG. 1. This type of thruster is referred to as an electron-bombardment ion thruster, and includes a cathode 2, propellant feedline 3, anode 4, power supply 5, neutralizer 6, magnet 7, and ion optics 8. The general operation of an ion thruster is described in the Background of the Invention and is not repeated here.
Additional details regarding ion thrusters, and particularly ion optics 8, are set forth in Hedges and Meserole, Demonstration and Evaluation of Carbon-Carbon Ion Optics, to be published in JOURNAL OF PROPULSION AND POWER and Garner and Brophy, Fabrication and Testing of Carbon-Carbon Grills for Ion Optics, AMERICAN INSTITUTE OF AERONAUTICS AND ASTRONAUTICS, 92-3149 (1992), the disclosures of which are hereby incorporated by reference.
Referring now to FIG. 2, the ion optics set 8 is shown in greater detail, as including a screen grid 20 and an accelerator grid 50. An optional decelerator grid 10, shown in FIG. 1 but not FIG. 2, may also be employed. Screen grid 20 and accelerator grid 50 are secured to the frame of the ion thruster (not shown) by annular dish-shaped mounting rings 12 and 14, respectively, whose spacing is controlled by spacers 16. It should be understood that the benefits and advantages of the present invention will be applicable to ion beam sources that are used for applications other than ion thrusters.
In the embodiment shown in FIG. 2, screen grid 20 is a substantially planar element that is a carbon-carbon composite comprising a carbon fiber array embedded in a carbon matrix. Referring additionally to FIG. 10, screen grid 20 includes an entry plane 22 and an opposing exit plane 24. As described in more detail below, entry plane 22 and exit plane 24 are substantially parallel which provides a screen grid of substantially uniform thickness. In the illustrated embodiment, screen grid 20 has a thickness on the order of about 0.8 millimeters (mm) and includes an array of apertures 26. Each aperture is approximately 10 centimeters (cm) in diameter. It should be understood that the foregoing dimensions are illustrative only; different diameters and thicknesses could be employed. For ion thrusters, it would be preferred to have the grids thinner, e.g., on the order of 0.4 mm, and larger in diameter, e.g., up to 50 cm or more, if possible. Thinner grids are preferred from the standpoint of increasing the electric field strength. Thickness is important from handling, assembly, and lifetime viewpoints, but the goal is to make the grids as thin as possible while retaining stiffness, uniformity, and the other required assembly properties.
Adjacent the periphery of screen grid 20 are a plurality of equally spaced mounting holes 28, shown in FIG. 3, that extend through screen grid 20 from entry plane 22 to exit plane 24. As described above, the central portion of screen grid 20 includes a plurality of round apertures 26 that extend through screen grid 20 from entry plane 22 to exit plane 24. As shown in FIG. 10, apertures 26 have a diameter at entry plane 22 that is greater than the diameter at exit plane 24. In this manner, apertures 26 have a vertical profile that narrows from entry plane 22 to exit plane 24. In the illustrated embodiment, screen grid 20 includes approximately 1,600 apertures that have a hole diameter of approximately 1.83 mm. The open area fraction through screen grid 20, then, is about 0.59. The spacing between the center points of adjacent apertures 26 is approximately 2.29 min.
In the illustrated embodiment, apertures 26 in screen grid 20 are arranged in a hexagonal array. The hexagonal array provides an aperture at the center of a hexagon with other apertures centered on the intersection of the six sides of a hexagon. Such hexagonal array is more clearly illustrated in FIG. 7, which is a magnified view of a portion of entry plane 22 of screen grid 20.
Referring to FIG. 7 in more detail, screen grid 20 includes carbon fibers 30 arranged in an array between apertures 26 and carbon matrix 38 that is infiltrated into the array. In the illustrated embodiment, carbon fibers 30 are arranged parallel to three different axes. Sets of carbon fibers 30 are arranged parallel to a first axis 32. Other carbon fibers 30 are arranged parallel to a second axis 34. In the illustrated embodiment, first axis 32 is offset from second axis 34 by 60°. A third group of fibers 30 is arranged parallel to a third axis 36. Third axis 36 is offset from both the first axis 32 and second axis 34 by 60°. In the illustrated embodiment, spacing between the periphery of apertures 26 is large enough that carbon fibers 30 can extend in a straight line from edge to edge of screen grid 20. As described below in more detail, when apertures 26 are larger and the carbon fibers cannot be run in a straight run from edge to edge, the carbon fibers can be "snaked" around the apertures, as shown in FIG. 8, where screen grid 20 includes fibers 42, carbon matrix 43, and apertures 40 that are larger diameter than apertures 26 illustrated in FIGS. 2 and 6. As noted above, when apertures 40 attain a certain diameter, carbon fibers 42 cannot extend in a straight line from edge to edge of screen grid 20. To achieve this "snaking" of the carbon fibers, the array can be laid up on a pattern of pegs or inserts that serve to define apertures 40.
It is also possible that in specific applications the size of the apertures passing through the screen grid will make it possible to have some fibers run in a straight line between the edges of the screen grid and other fibers that "snake" around the apertures.
Referring to FIG. 4, another embodiment of screen grid 20 is illustrated having apertures 44 that are hexagonal in shape and arranged in a hexagonal array. Depending on the dimensions of hexagonal apertures 44, carbon fibers can extend from edge to edge of the screen grid in a straight line or they may be "snaked" around hexagonal apertures 44 as described above. Under certain operating conditions, hexagonal holes may provide slightly better thruster performance than round holes.
Referring to FIG. 5, another embodiment of screen grid 20 formed in accordance with the present invention is illustrated with apertures 46 that are rectangular in shape. When rectangular apertures 46 are employed, they can be arranged in orthogonal rows and columns or any other suitable arrangement. When apertures 46 are arranged in orthogonal rows and columns, carbon fibers 48 infiltrated with carbon matrix 49 extend in straight lines (FIG. 9) from edge to edge of the screen grid in an orthogonal array. This arrangement offers the advantage of providing orthogonal straight paths for the fibers across the entire grid, thereby maximizing the grid's stiffness.
As an alternative to arranging individual carbon fibers or tows of carbon fibers in the arrays described above, pre-woven sheets of carbon fibers can be arranged in layers to provide the needed carbon fiber array. When sheets of woven carbon fibers are used, the sheets can be arranged in layers that are offset, for example by 60°, from each other with respect to the direction of the weave or in any other suitable pattern. Pre-woven sheets of carbon fibers are preferred over the individual tows of fibers from an ease of handling perspective; however, the pre-woven sheets are generally thicker than the individual fibers or tows and therefore are not preferred from the standpoint of providing a thin grid.
Referring to FIG. 6, the accelerator grid 50 is substantially identical to screen grid 20 described above with the exception that the size of apertures 52 is much less so as to restrict the flow of neutral atoms out of the thruster. The electric field between the screen and accelerator grid is shaped so as to focus the ions passing through the large screen grid apertures into and through the smaller accelerator grid apertures. For example, for screen grid 20 described with reference to FIG. 2, a counterpart accelerator grid could include apertures 52 having a diameter of about 1.09 mm. Such an accelerator grid would have an open area fraction of about 0.29. Accelerator grid 50 has substantially the same number of apertures 52 as the screen grid and when the two are combined to form an ion optics pair, the axes of the apertures of the screen grid and the axes of the apertures of the accelerator grid are aligned.
The screen grid and the accelerator grid can both include hexagonal apertures or rectangular apertures arranged in the same manner as described above, or other arrays suitable for the application. Similarly, one could vary the size of apertures as a function of their position in the grids to match the distribution of plasma over the grids.
Referring to FIG. 11, as with the screen grids, accelerator grid 50 includes an entry plane 53 and an opposing exit plane 55. Entry plane 53 and exit plane 55 are substantially parallel so that the accelerator grid has a substantially uniform thickness. The diameter of aperture 52 at entry plane 53 is less than the diameter of aperture 52 at exit plane 55. In this manner, aperture 52 has a profile through accelerator grid 50 that is tapered from entry plane 53 to exit plane 55.
The carbon fibers that can be used in the context of the present invention include those that are commercially available from a number of sources, including the K-1100 high modulus fiber available from the Amoco Company or the E-55 fiber available from the DuPont Company. Such fibers are usually drawn and may be interwoven to provide tows or sheets of fibers. The fibers available exhibit a range of physical properties. For ion thrusters, fibers having an elastic modulus on the order of 4×10 5 MPa to 1×10 6 MPa and a diameter of about 10 microns are suitable. Carbon fibers having an elastic modulus on the upper end of the foregoing range will generally allow thinner grids of adequate overall stiffness to be made than will carbon fibers having an elastic modulus near the lower end of the range. Stiffer fibers are generally preferred; however, they should also have commensurate strength so as not to be brittle and fragile during handling. Grids made with carbon fibers near the lower end of the range will require appropriate thermal processing after forming to increase the fiber modulus to a higher value, preferably above 100 million psi.
A carbon matrix is built around the carbon fiber array by a repetitive process. Each repetition of the process involves the steps of infiltration with a carbonaceous material, as described below, and high-temperature pyrolysis. The carbonaceous materials can be pitch, resin, or organic gases. A combination of these materials also may be used, although only one material is used in any given infiltration and pyrolysis sequence. Pyrolysis is a thermal process which decomposes the carbonaceous precursor material to leave a residue of pure carbon as the carbon matrix around the carbon fiber array. The process of building the carbon matrix is referred to as densification because the density is increased as fibers become embedded in the carbon matrix.
Pitch and resin infiltration is accomplished by pouring or squeezing the pitch or resin into the carbon fiber array. This infiltration can also be effected by using carbon fibers or tows of carbon fibers that have been laid up on a tape and preimpregnated with pitch or a phenolic polymer. Two companies that perform pitch or resin infiltration are Fiber Materials, Inc., of Biddeford, Me. and Kaiser Aerotech of San Leandro, Calif.
Organic gas infiltration, otherwise known as chemical vapor infiltration, is generally carried out in a controlled atmosphere furnace where an organic gas infiltrates the carbon fiber array, decomposes at the surfaces, and leaves a carbon residue which binds the fibers together and forms a continuous matrix. One company that provides chemical vapor infiltration services is B. F. Goodrich of Sante Fe Springs, Calif.
Although the described screen and accelerator grids are planar, in certain applications, it may be desirable to curve the grid a small amount to add stiffness.
As noted previously, the screen grid 20 and accelerator grid 50 are coupled to the frame of the ion thruster by mounting rings 12 and 14. Rings 12 and 14 are also preferably formed using the same carbon-carbon composite employed in the grids, although alternative materials can be employed. A greater variety of fiber arrays can also be used in rings 12 and 14, given the absence of the grid apertures. Each ring includes a central opening 18 dimensioned to enclose the apertured region of the grid it is used with. Each ring includes a plurality of grid mounting holes 19 and frame mounting holes 21.
The mounting rings 12 and 14 are attached to grids 20 and 50 via the grid mounting holes 19 and mounting screws 23. The rings are also attached to the thruster frame by screws (not shown). Alignment pins would typically be employed to achieve the desired relative alignment of these various components.
The carbon-carbon grids and mounting rings do not expand upon heating. In fact, they might contract, but only slightly. Their coefficient of thermal expansion is essentially zero. Since expansion of the grids and mounting rings is negligible over the operational temperature gradients, which can be on the order of 350 degrees Celsius, alignment of the apertures and a constant spacing between the screen grid and the accelerator grids can be better maintained. When spacing between the grids can be reliably maintained constant during the operational temperature changes, the grids can be spaced closer together without the risk that expansion will cause the grids to touch each other and be electrically shorted together, or that the beam density will be excessive where the gap is smaller than intended. Shorting destroys the voltage gradient needed to accelerate the ions. Excessive beam densities increase the production of charge exchange ions that increase grid erosion. Also, when the spacing can be maintained constant, larger grid diameters can be designed without increasing the likelihood that thermal expansion will adversely affect performance. Large grid diameters can translate into efficiency, thrust-to-weight, and reliability advantages.
In addition to the foregoing advantages, carbon-carbon grids are more resistant to erosion by ions than the materials used today to make grids, such as molybdenum. Space applications require that such grids have a lifetime on the order of 10,000 hours. Carbon-carbon grids formed in accordance with the present invention show potential to exceed such lifetimes without restrictions imposed on the thruster operating conditions (specifically, without limiting the beam density for the purpose of reducing the erosion rate).
In accordance with the present invention, the screen and accelerator grids can be combined in a conventional manner to provide an ion optics set 8, as shown in FIG. 2, for use in the ion thruster 1 or other ion beam sources. When the carbon-carbon composite screen and accelerator grids are used in an ion optics set 8, grid spacings of approximately 0.2 mm to 0.5 mm can be used. Grid spacing outside the exemplary range given above can be employed in accordance with the present invention. The narrow grid spacing described above is achievable with the carbon-carbon grids because the thermal-mechanical stability of the carbon-carbon composite and the stiffness of the grids allows the screen and accelerator grids to be spaced closer together than conventional grids. The use of carbon-carbon composites for the mounting rings further contributes to the thermal-mechanical stability of the ion optics, hence, the ability of the grids to be closely spaced. Spacing the grids closer together increases the field strength between the grid, which increases the maximum achievable beam density. A carbon-carbon grid set is tested for voltage stand-off capability, maximum perveance condition, electron backstreaming limit and defocusing limit in the example that forms a part of this detailed description.
Generally, the fabrication of the grids described above includes selecting a high-modulus carbon fiber, an appropriate lay-up pattern, a suitable means of densification, and a method for making apertures of the desired shape and arrangement. Minimizing the thicknesses of the screen grid and accelerator grid, subject to structural and erosion constraints, is also an important design consideration.
The carbon fibers can be laid up on a solid substrate in any of the patterns described above. The substrate that is chosen should be compatible with the subsequent infiltrating step. For example, a flat carbon block may be suitable as a base for laying up the fibers. The carbon fibers should be laid up in as dense an arrangement as possible given the desired thickness of the particular grid. Thinner grids may be desirable; however, as the grids are made thinner, care must be taken that they do not become too flexible. With respect to the particular form of the fiber chosen, tapes of fibers or tows are preferred over woven fabrics since woven fabrics tend to introduce added thickness at the points of the overlapping weaves and the curing of the fibers in the weave reduces the effective grid stiffness. When fabric is used, the fibers may be used in an amount that they comprise approximately 50-65 volume percent of the overall grid and when a tape is used the fibers comprise approximately 75-90 volume percent of the grid. Generally, the higher the volume percent fibers, the stiffer the grid.
As described above, the lay-up of fibers can be densified using techniques such as pitch infiltration, resin infiltration, or chemical vapor infiltration. Pitch infiltration can be used to fill the larger internal voids and the smaller voids can be filled with chemical vapor infiltration. Since neither densification method provides a void-free body, to improve the erosion resistance, internal voids exposed when the apertures are cut, as described below in more detail, should be filled by chemical vapor infiltration. The densification steps preferably provide a carbon-carbon composite having a density greater than 1.9 g/cm 3 . Accordingly, when the grid comprises about 50 volume percent fibers, the carbon matrix will comprise approximately 50 volume percent of the grid. Similarly, when the grid comprises about 90 volume percent fibers, the carbon matrix will comprise approximately 10 volume percent of the grid.
The apertures in the grids can be cut by several different methods. For example, for round apertures, you can use mechanical drilling with diamond tip drills, or faster cutting methods, such as laser cutting, ultrasonic milling, water jet cutting, or electron discharge machining, can be employed.
For some applications, you may prefer to employ a technique providing uniformly tapered apertures of the type described above. Such apertures advantageously enable a wider range of operating conditions without the beam impinging upon the side walls of the apertures. As a result, thicker grids can be employed to achieve the desired grid stiffness, without incurring a performance penalty. You may also wish to remove the "sharp" perimeter of the openings of the aperture to reduce erosional effects at the openings.
Alternatively, you can form the apertures by providing a pattern of pegs or other inserts around which the carbon fibers are laid up and around which the carbon infiltration of the array is carried out. In this manner, the apertures will be preformed rather than requiring subsequent drilling after infiltration.
EXAMPLE
We made a 10-cm diameter, flat, circular screen grid and a 10-cm diameter, flat, circular accelerator grid from two 14-cm square carbon-carbon panels we obtained from B. F. Goodrich of Sante Fe Springs, Calif. The panels consisted of three plys of carbon fiber fabric densified by chemical vapor infiltration. The fibers making up the fabric had an elastic modulus of about 105 million psi. The infiltrated panels were 0.8 mm thick and were machined to include 1,615 apertures. The apertures in the accelerator grid had a diameter of 1.09 mm and the apertures in the screen grid were 1.83 mm in diameter. The screen grid had an open area fraction of 0.59 and the accelerator grid had an open area fraction of 0.21. Hole spacing between the apertures in both grids was 2.29 mm and the hole profile was a tapered 6° cut, which was a result of the particular laser cutting operation used to produce the apertures.
No special surface preparation, either cleaning or smoothing, was done prior to testing. The laser machining process left a soot-like discoloration on the laser entry side of each grid. The surface roughness due to the fiber weave was about 0.05 mm. When mounted, these grids were measured to be flat to within 0.025 mm.
Optics tests were conducted using a 15-cm ion source produced by Ion Tech, Inc. of Fort Collins, Colo. An adapter was used to mask down the 15-cm source to 10 cm and to accept a separate conventional molybdenum grid mount that was used to mount the carbon-carbon grids.
The ion source used tungsten filaments for both the cathode and the neutralizer. Variable alternating current sources (variacs) drove the cathode and neutralizer. We isolated the cathode from its variac using an isolation transformer. The beam supply was rated at 3,000 volts and 1 amp and was referenced to facility ground. The discharge supply floated at beam potential with its positive terminal connected to the positive terminal of the beam supply and its negative terminal connected to tile mid-point of the secondary winding on the cathode isolation transformer. The discharge supply was rated at 200 volts and 17 amps. The accelerator supply was rated at 600 volts and 1.5 amps. The tests were conducted using xenon as the propellant, although other inert gases (such as argon and krypton), or other elements or molecules (such as mercury, or carbon-60) can be employed.
We conducted the tests in a diffusion pumped vacuum chamber, 0.9 meters in diameter by 1.8 meters in height, that maintained approximately 5×10 -5 tort during testing. With a digital data acquisition system, beam voltage and current, accelerator grid voltage and current, discharge voltage and current, cathode filament current, neutralizer filament, and emission current, and propellant flow were measured. Vacuum chamber pressure was measured with an ion gauge.
Before operating the grids on the thruster, we conducted voltage standoff tests. The optics set was mounted to the molybdenum grid mount, gapped to 0.58 mm and then tested until voltage breakdown occurred in both air and vacuum using a high voltage, variable DC power supply. A 100K ohm power resistor was placed in series with the high voltage power supply to limit the current when arcing occurred.
With the carbon-carbon grids installed in the grid mount at a gap setting of 0.58 mm, and exposed to atmospheric conditions, we increased the voltage across the grids slowly. Arcing was observed initially as the voltage was increased above 1,000 volts, but by pausing the increase at each occurrence, the rate of arcing decreased, and eventually stopped. The voltage was increased to 2,500 volts. After some initial arcing, the voltage was held at 2,500 volts for several minutes until no further arcing was observed. The voltage gradient at that point was 4,300 volts per min. Inspection of the grids under a microscope following the tests showed that the arcing had no visible effect on the grids, other than to produce some slight, localized surface discoloration.
We repeated the procedure in a vacuum chamber pumped down to 1×10 -5 torr. No arcing was visible up to 3,500 volts. At 3,500 volts, a small, steady current of about 0.5 milliamps was observed on the power supply analog current meter. At 3,750 volts, arcing began, but it subsided with time. Eventually, 5,000 volts with only occasional arcing was reached, but a steady current of 1 milliamp was recorded. At 5,250 volts, arcing was observed. At 5250 volts, the voltage gradient was 9050 V/mm. Maximum voltage gradients of 6420 V/mm during operation at 0.2 mm spacing for the carbon-carbon grids was also observed.
Three grid-to-grid gaps of 0.2 mm, 0.3 mm, and 0.5 mm were chosen at which to operate the thruster. These gaps provided effective acceleration lengths of 1.35 mm, 1.42 mm, and 1.58 min.
Prior to starting the thruster for each run, the chamber background pressure was recorded while xenon flowed at the rate desired for that run. The thruster was then started and allowed to warm up for at least 30 minutes prior to data acquisition. For all runs, the initial run conditions were as follows:
(1) the propellant utilization efficiency (η p ) was set to approximately 75%, determined by the ratio of beam current to propellant flow rate, where flow rate was convened to an equivalent current flow using 1 amp equal to 13.95 standard cubic centimeters per minute for singly ionized atoms.
(2) the discharge voltage V d was set to 35 volts, which was less than or equal to 10% of the total accelerating voltage V t . The total accelerating voltage is given by V t =V b +|V a | where V b is the beam (and also the net accelerating) voltage and |V a | is the absolute value of the accelerator grid voltage.
(3) the net to total voltage ratio R was set to 0.8, where R=V b /V t ; and
(4) the total voltage was set high enough to preclude direct ion impingement (by choosing a V t such that further increases in V t at a fixed R did not reduce accelerator grid impingement current).
Perveance expresses total current in terms of applied voltage. For a fixed beam current, the maximum perveance condition of an ion optics set occurs at the minimum total voltage (V t ) prior to the onset of direct ion impingement. For the carbon-carbon grids, we measured accelerator grid impingement current as a function of decreasing beam voltage to identity the minimum total voltage prior to direct ion impingement. We made measurements for each of five beam current (J b ) levels from 80 milliamps to 160 milliamps, and for an acceleration length of 1.35 mm. We held beam current constant by adjusting the discharge current as necessary in response to changes in the beam voltage. Accelerator grid voltage was fixed for each run. FIG. 12 shows a representative plot of accelerator grid impingement current (J a ) as a function of beam voltage (V b ) for the carbon-carbon optics.
Electron backstreaming occurs when the accelerator grid voltage is no longer sufficient to shield external electrons from the positive potential of the discharge chamber. Electrons are then free to flow from the external environment into the discharge chamber.
After completing each data run for determining the maximum perveance condition, the initial conditions were reestablished and then beam current (J b ) was measured as a function of decreasing accelerator grid voltage (V a ) for each of the effective acceleration lengths. The accelerator grid voltage was slowly reduced as the analog current meter on the beam supply was monitored. As the accelerator grid voltage fell below the electron backstreaming limit, a rapid increase in beam current was observed. The accelerator grid voltage at which this beam current occurred was recorded as the electron backstreaming limit. FIG. 13 represents plots of the electron backstreaming limit for each run.
After completing each data run for determining the electron backstreaming limit, the initial run conditions were reestablished. For an effective acceleration length of 1.42 mm, accelerator grid impingement current as a function of net-to-total voltage ratio (R) was measured while holding total voltage (V t ) constant. This determined the minimum R prior to the onset of direct ion impingement. For the selected total voltage, R was adjusted down from an initial value of 0.8 by decreasing the beam voltage, then increasing the accelerator grid voltage by the same amount, thereby lowering the beam (net) voltage while maintaining a fixed total voltage. At each step, accelerator grid impingement current was recorded. As the defocusing limit was approached, the accelerator grid impingement current increased from the background level. The value of R at which the accelerator grid current first increased above the background level was identified as the defocusing limit for each run condition. FIG. 14 shows the ratio of accelerator grid impingement current (J a ) to beam current (J b ) plotted as a function of R. For the carbon-carbon optics at an effective acceleration length of 1.42 millimeters, the defocusing limit occurred for R values between 0.4 and 0.5.
During these tests, we did not observe buckling or breaking of the ion optics. Accordingly, this test also demonstrates how fiat carbon-carbon ion optics made have sufficient thermomechanical stability to operate with grid spacings on the order of 0.2 mm.
While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. | Carbon-carbon elements for ion optics sets are thermomechanically stable under the extreme temperature changes that are experienced in ion thrusters. The elements described include screen and accelerator grids and methods of producing such grids. The described elements are thermomechanically stable, lightweight, and resistant to sputtering. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to Japanese Patent Application No. 2012-055103 filed Mar. 12, 2012, the content of which is hereby incorporated herein by reference.
BACKGROUND
The present disclosure relates to a sewing machine, an embroidery unit, and a non-transitory computer-readable medium storing a sewing machine control program that allow sewing in a position specified on a work cloth.
A sewing machine is known that can easily set a sewing position and a sewing angle, at which a desired embroidery pattern is to be sewn, on a work cloth. For example, a known sewing machine includes an imaging portion. After a user affixes a marker to a specified position on the work cloth, an image of the marker may be captured by the imaging portion. The sewing machine may automatically set the sewing position and the sewing angle of the embroidery pattern based on the captured image of the marker.
SUMMARY
However, with the above-described sewing machine, it may be necessary to affix the marker to the work cloth. Further, after the sewing machine has set the sewing position and the sewing angle of the embroidery pattern, the user may need to remove the marker affixed to the work cloth before sewing is performed. Therefore, the operation may be troublesome for the user.
Embodiments of the broad principles derived herein provide a sewing machine, an embroidery unit, and a non-transitory computer-readable medium storing a sewing machine control program that enable easily setting a position, on a work cloth, at which sewing is performed.
Embodiments provide a sewing machine that includes at least one detecting portion, a processor, and a memory. The at least one detecting portion is configured to detect an ultrasonic wave that has been transmitted from a transmission source. The memory is configured to store computer-readable instructions that instruct the sewing machine to execute steps including identifying a position of the transmission source of the ultrasonic wave based on information pertaining to the ultrasonic wave that has been detected by the at least one detecting portion, and controlling sewing based on the position of the transmission source that has been identified.
Embodiments also provide an embroidery unit that can be attached to and detached from a bed of a sewing machine, and to which an embroidery frame can be attached, and that is configured to move the embroidery frame, the embroidery frame being configured to hold a work cloth. The embroidery unit includes at least one detecting portion and a notifying portion. The at least one detecting portion is configured to detect an ultrasonic wave that has been transmitted from a transmission source. The notifying portion is configured to notify the sewing machine of a detection timing at which the ultrasonic wave was detected by the at least one detecting portion. The embroidery unit is configured to move the work cloth based on a position of the transmission source of the ultrasonic wave that has been identified by the sewing machine based on the detection timing that has been notified by the notifying portion.
Embodiments further provide a non-transitory computer-readable medium storing a control program executable on a sewing machine. The program includes computer-readable instructions, when executed, to cause the sewing machine to perform the step of identifying, based on information pertaining to an ultrasonic wave that has been detected by at least one detecting portion of the sewing machine, a position of a transmission source of the ultrasonic wave. The at least one detecting portion is configured to detect the ultrasonic wave that has been transmitted from the transmission source. The program further includes computer-readable instructions, when executed, to cause the sewing machine to perform the step of controlling sewing based on the position of the transmission source that has been identified.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments will be described below in detail with reference to the accompanying drawings in which:
FIG. 1 is a front view of a sewing machine according to a first embodiment;
FIG. 2 is a perspective view of a receiver;
FIG. 3 is a front view of the receiver;
FIG. 4 is a cross-sectional view of the receiver taken along a line I-I shown in FIG. 3 , as seen in an arrow direction;
FIG. 5 is a block diagram showing an electrical configuration of the sewing machine and an ultrasonic pen according to the first embodiment;
FIG. 6 is a diagram illustrating a calculation method of specified coordinates E according to the first embodiment;
FIG. 7 is a flowchart showing main processing according to the first embodiment;
FIG. 8 is a front view of the sewing machine according to a second embodiment;
FIG. 9 is a plan view of an embroidery unit according to the second embodiment;
FIG. 10 is a right side view of the embroidery unit according to the second embodiment;
FIG. 11 is a front view of a sewing machine according to a third embodiment;
FIG. 12 is a block diagram showing an electrical configuration of the sewing machine and an ultrasonic pen according to the third embodiment;
FIG. 13 is a front view of a sewing machine according to a fourth embodiment;
FIG. 14 is a diagram illustrating a calculation method of specified coordinates E according to the fourth embodiment;
FIG. 15 is a flowchart showing main processing according to the fourth embodiment;
FIG. 16 is a front view of a sewing machine according to a fifth embodiment;
FIG. 17 is a right side view of a multi-needle sewing machine according to the fifth embodiment; and
FIG. 18 is a plan view of an embroidery frame movement mechanism according to the fifth embodiment.
DETAILED DESCRIPTION
First Embodiment
Hereinafter, a first embodiment will be explained with reference to the drawings. A configuration of a sewing machine 1 will be explained with reference to FIG. 1 . The near side, the far side, the upper side, the lower side, the left side, and the right side of FIG. 1 are respectively defined as the front side, the rear side, the upper side, the lower side, the left side, and the right side of the sewing machine 1 . Specifically, a direction in which a pillar 12 , which will be described below, extends is the up-down direction of the sewing machine 1 . The longitudinal direction of a bed 11 and an arm 13 is the left-right direction of the sewing machine 1 . A surface on which a plurality of operation switches 21 are arranged is a front face of the sewing machine 1 .
The sewing machine 1 includes the bed 11 , the pillar 12 , the arm 13 , and a head 14 . The bed 11 is a base portion of the sewing machine 1 and extends in the left-right direction. The pillar 12 extends upward from the right end of the bed 11 . The arm 13 extends to the left from the upper end of the pillar 12 such that the arm 13 faces the bed 11 . The head 14 is provided on the left end of the arm 13 . A needle plate 34 is disposed on a top surface of the bed 11 . A feed dog, a feed mechanism, a shuttle mechanism (which are not shown in the drawings) and a feed adjustment motor 83 (refer to FIG. 5 ) are provided below the needle plate 34 (namely, inside the bed 11 ). The feed dog may be driven by the feed mechanism, and may feed a work cloth 100 (refer to FIG. 6 ) by a specified feed distance. The feed adjustment motor 83 may adjust the feed distance of the feed dog.
A needle bar mechanism (not shown in the drawings), a needle bar swinging motor 80 (refer to FIG. 5 ) and the like are provided on the head 14 . The needle bar mechanism may drive a needle bar 29 in the up-down direction. A sewing needle (not shown in the drawings) may be attached to the needle bar 29 . The needle bar swinging motor 80 may swing the needle bar 29 in the left-right direction. A receiver 94 is provided at the lower left end of the head 14 , on the rear side of a lower surface of the head 14 . A receiver 95 is provided at the lower right end of the head 14 , on the rear side of the lower surface of the head 14 . The receivers 94 and 95 are separated from each other in the left-right direction by the length of the head 14 in the left-right direction. The receivers 94 and 95 are configured to receive (detect) an ultrasonic wave. The receivers 94 and 95 have the same configuration. The receivers 94 and 95 will be described in more detail later.
A cover 16 to be opened and closed is provided on an upper portion of the arm 13 . A thread spool (not shown in the drawings) may be accommodated underneath the cover 16 , that is, substantially in a central portion within the arm 13 . An upper thread (not shown in the drawings) may be wound around the thread spool. The upper thread may be supplied from the thread spool, through a thread hook (not shown in the drawings), to the sewing needle attached to the needle bar 29 . The thread hook is provided on the head 14 . The needle bar mechanism, which is provided inside the head 14 , may drive the needle bar 29 such that the needle bar 29 is moved up and down. The needle bar mechanism may be driven by a sewing machine motor 79 (refer to FIG. 5 ). A presser bar 31 extends downward from the lower end of the head 14 . A presser foot 30 may be detachably attached to the lower end of the presser bar 31 . The presser foot 30 may press down the work cloth 100 . The plurality of operation switches 21 are provided on a lower portion of the front face of the arm 13 . The plurality of operation switches 21 include a start/stop switch.
A liquid crystal display (LCD) 15 is provided on the front face of the pillar 12 . The LCD 15 may display images that include various types of items, such as a command, an illustration, a set value, a message, and the like. A touch panel 26 is provided on the front face of the LCD 15 . A user may perform an operation of pressing the touch panel 26 using a finger or a dedicated touch pen. Hereinafter, this operation is referred to as a “panel operation”. The touch panel 26 detects a position pressed by the finger, the dedicated touch pen, or the like, and the sewing machine 1 (more specifically, a CPU 61 that will be described below) determines the item that corresponds to the detected position. In this manner, the sewing machine 1 recognizes the selected item. By the panel operation, the user can select a pattern to be sewn and a command to be executed.
Connectors 39 and 40 are provided on a right surface of the pillar 12 . An external storage device (not shown in the drawings), such as a memory card, can be connected to the connector 39 . The sewing machine 1 may read out pattern data and various programs from the external storage device connected to the connector 39 . A connector 916 may be connected to the connector 40 . The connector 916 is coupled to a cable 912 that extends from an ultrasonic pen 91 (which will be described below). The sewing machine 1 may supply electric power to the ultrasonic pen 91 via the connector 40 , the connector 916 , and the cable 912 , and may acquire an electrical signal output from the ultrasonic pen 91 .
The ultrasonic pen 91 will be explained. The ultrasonic pen 91 includes a pen body 910 and a pen tip 911 . The pen body 910 has a bar shape. The pen tip 911 is provided at the leading end of the pen body 910 . A point of the pen tip 911 is sharp. Normally, the pen tip 911 is in a protruding position in which the pen tip 911 protrudes slightly to the outside from the pen body 910 . On the other hand, when a force toward the pen body 910 acts on the pen tip 911 , the pen tip 911 is inserted into the pen body 910 . When the force acting on the pen tip 911 is released, the pen tip 911 returns to the original protruding position.
The ultrasonic pen 91 includes a switch 913 (refer to FIG. 5 ), a signal output circuit 914 (refer to FIG. 5 ), and an ultrasonic transmitter 915 (refer to FIG. 5 ) inside the pen body 910 . The switch 913 is turned on and off in accordance with the position of the pen tip 911 . The switch 913 may switch output states of the signal output circuit 914 and the ultrasonic transmitter 915 .
When no force acts on the pen tip 911 (when the pen tip 911 is in the protruding position), the switch 913 is in an OFF state. When the switch 913 is in the OFF state, the signal output circuit 914 does not output an electrical signal and the ultrasonic transmitter 915 does not output an ultrasonic wave. On the other hand, when the user presses the pen tip 911 against an arbitrary position on the work cloth 100 , a force acts on the pen tip 911 . At this time, the pen tip 911 is inserted into the pen body 910 and the switch 913 is turned on. When the switch 913 is turned on, the signal output circuit 914 outputs an electrical signal to the sewing machine 1 via the cable 912 , and the ultrasonic transmitter 915 transmits an ultrasonic wave.
As will be described in detail below, the sewing machine 1 can receive (detect) the ultrasonic wave transmitted from the ultrasonic pen 91 using the receivers 94 and 95 . Based on the detected ultrasonic wave, the sewing machine 1 can identify a transmission source of the ultrasonic wave, namely, the position of the ultrasonic transmitter 915 provided in the ultrasonic pen 91 . The sewing machine 1 can perform sewing based on the identified position. Thus, the user can specify an arbitrary position on the work cloth 100 by pressing the pen tip 911 of the ultrasonic pen 91 on the work cloth 100 (touching the work cloth 100 with the pen tip 911 ). As a result, it is possible to perform sewing in the specified position.
The receiver 94 will be explained with reference to FIG. 2 to FIG. 4 . The receiver 95 has the same configuration as that of the receiver 94 , so an explanation thereof is omitted. The lower left side, the upper right side, the upper left side, the lower right side, the upper side, and the lower side of FIG. 2 are respectively defined as the front side, the rear side, the left side, the right side, the upper side, and the lower side of the receiver 94 .
As shown in FIG. 2 and FIG. 3 , the receiver 94 has a rectangular parallelepiped shape that is slightly longer in the up-down direction. An opening 941 is provided in the center of a lower end portion of the front face of the receiver 94 . The opening 941 has an elliptical shape that is long in the left-right direction. A wall 942 around the opening 941 is a tapered surface (an inclined surface) that becomes narrower from the outer side toward the inner side of a front surface of the receiver 94 . As shown in FIG. 4 , a substrate 943 and a microphone 944 are provided inside the receiver 94 . The microphone 944 is provided, inside the receiver 94 , behind the opening 941 . A connector 945 is mounted on an upper end of a rear surface of the substrate 943 . The connector 945 may be connected to a connector (not shown in the drawings) that is provided on the sewing machine 1 . An orientation of the receiver 94 is determined by a direction of the opening 941 in relation to the microphone 944 .
An electrical configuration of the sewing machine 1 and the ultrasonic pen 91 will be explained with reference to FIG. 5 . A control portion 60 of the sewing machine 1 includes a CPU 61 , a ROM 62 , a RAM 63 , an EEPROM 64 , and an input/output interface 65 , which are mutually connected via a bus 67 . The ROM 62 stores programs and data etc. that are used by the CPU 61 to execute processing. The EEPROM 64 stores data of various types of sewing patterns that are used for the sewing machine 1 to perform sewing.
The operation switches 21 , the touch panel 26 , and drive circuits 71 , 72 , 74 , 75 , and 76 are electrically connected to the input/output interface 65 . The drive circuits 71 , 72 , 74 , 75 , and 76 may respectively drive the feed adjustment motor 83 , the sewing machine motor 79 , the needle bar swinging motor 80 , the LCD 15 , the receiver 94 , and the receiver 95 . The drive circuit 76 includes an amplification circuit. The amplification circuit may amplify ultrasonic signals detected by the receivers 94 and 95 , and may transmit the amplified signals to the CPU 61 .
The electrical configuration of the ultrasonic pen 91 will be explained. The ultrasonic pen 91 includes the switch 913 , the signal output circuit 914 , and the ultrasonic transmitter 915 . The switch 913 is connected to the signal output circuit 914 and the ultrasonic transmitter 915 . The signal output circuit 914 can be connected to the input/output interface 65 . The signal output circuit 914 may output an electrical signal to the CPU 61 via the input/output interface 65 .
A method of identifying a position on the work cloth 100 specified using the ultrasonic pen 91 will be explained with reference to FIG. 6 . The user may cause the pen tip 911 of the ultrasonic pen 91 to touch the work cloth 100 , and thereby may specify a position on the work cloth 100 where sewing is to be performed by the sewing machine 1 . Hereinafter, a position on the work cloth 100 that is touched by the pen tip 911 of the ultrasonic pen 91 is also referred to as a specified position. As described below, the sewing machine 1 may identify a specified position by identifying a position of a transmission source of an ultrasonic wave. Therefore, strictly speaking, the position of the ultrasonic transmitter 915 provided in the ultrasonic pen 91 is identified, rather than the position on the work cloth 100 touched by the pen tip 911 . The pen tip 911 and the ultrasonic transmitter 915 are arranged very close to each other. Therefore, the position of the ultrasonic transmitter 915 may be assumed as the position on the work cloth 100 touched by the pen tip 911 , namely, the specified position. Hereinafter, the left-right direction, the front-rear direction, and the up-down direction of the sewing machine 1 are respectively defined as an X direction, a Y direction, and a Z direction. The left-right direction and the up-down direction of FIG. 6 respectively correspond to the X direction and the Y direction. A direction from the near side to the far side corresponds to the Z direction.
The sewing machine 1 identifies the specified position as coordinate information (an X coordinate, a Y coordinate, and a Z coordinate). Here, the coordinate origin (0, 0, 0) is defined as a center point of a needle hole. The needle hole is formed in the needle plate 34 (refer to FIG. 1 ), and is a hole through which the sewing needle may pass. The center point of the needle hole is a needle drop point, which will be described below. The Z coordinate of a top surface of the needle plate 34 is 0. Coordinates B that indicate the position of the receiver 94 are denoted by (Xb, Yb, Zb). Coordinates C that indicate the position of the receiver 95 are denoted by (Xc, Yc, Zc). Coordinates E that indicate the specified position are denoted by (Xe, Ye, Ze), The Z coordinate of the receivers 94 and 95 indicates the height of the receivers 94 and 95 with respect to the top surface of the needle plate 34 . The coordinates B (Xb, Yb, Zb) and the coordinates C (Xc, Yc, Zc) are stored in advance in the ROM 62 . Hereinafter, the coordinates E are also referred to as “specified coordinates E”. A distance between the specified coordinates E and the coordinates B is referred to as a “distance EB”. A distance between the specified coordinates E and the coordinates C is referred to as a “distance EC”.
The distances EB and EC can be expressed by the coordinates B, C, and E based on the Pythagorean theorem. The distance EB and the coordinates B, C, and E satisfy a relationship of Formula (1) below. In a similar manner, the distance EC and the coordinates B, C, and E satisfy a relationship of Formula (2) below.
( Xb−Xe ) 2 +( Yb−Ye ) 2 +( Zb−Ze ) 2 =( EB ) 2 Formula (1)
( Xc−Xe ) 2 +( Yc−Ye ) 2 +( Zc−Ze ) 2 =( EC ) 2 Formula (2)
Formula (1) is the same as the equation of a spherical surface (whose radius is the distance EB), the origin of which is the coordinates B and on which the specified coordinates E is. In a similar manner, Formula (2) is the same as the equation of a spherical surface (whose radius is the distance EC), the origin of which is the coordinates C and on which the coordinates E is.
The speed at which an ultrasonic wave travels is assumed to be a sonic velocity V. A time required from when the ultrasonic wave is transmitted from the ultrasonic pen 91 at the specified coordinates E to when the ultrasonic wave reaches the receiver 94 is referred to as a propagation time Tb. A time required from when the ultrasonic wave is transmitted from the ultrasonic pen 91 at the specified coordinates E to when the ultrasonic wave reaches the receiver 95 is referred to as a propagation time Tc. In this case, the distances EB and EC are expressed by the following Formulas (3) and (4).
EB=V×Tb Formula (3)
EC=V×Tc Formula (4)
The following Formulas (5) and (6) are obtained by substituting Formulas (3) and (4) into Formulas (1) and (2) described above.
( Xb−Xe ) 2 +( Yb−Ye ) 2 +( Zb−Ze ) 2 =( V×Tb ) 2 Formula (5)
( Xc−Xe ) 2 +( Ye−Ye ) 2 +( Zc−Ze ) 2 =( V×Tc ) 2 Formula (6)
In Formulas (5) and (6), the coordinates B (Xb, Yb, Zb), the coordinates C (Xc, Yc, Zc) and the sonic velocity V are known values and stored in advance in the ROM 62 . The propagation time Tb and the propagation time Tc are each identified by calculating a difference between a transmission timing T 1 and a detection timing T 2 . The transmission timing T 1 is a timing at which the ultrasonic wave is transmitted from the ultrasonic transmitter 915 of the ultrasonic pen 91 . The detection timing T 2 is a timing at which the ultrasonic wave is detected by each of the receivers 94 and 95 . The thickness of the work cloth 100 is small enough to be ignored, in comparison to the values Xe and Ye. Therefore, the value Ze of the specified coordinates E (Xe, Ye, Ze) can be deemed to be zero. Thus, the values Xe and Ye can be calculated by solving the simultaneous equations represented by Formulas (5) and (6). Here, taking orientations of the receivers 94 and 95 into account, the specified coordinates E (Xe, Ye, Ze (=0)) on the work cloth 100 that are specified using the ultrasonic pen 91 can be determined.
It is preferable that the receivers 94 and 95 be provided in positions of the sewing machine 1 that satisfy the following conditions (A) to (E). In an explanation of the conditions (A) to (E), the receivers 94 and 95 are referred to as receivers 93 for convenience of the explanation.
(A) An object is unlikely to enter between the ultrasonic pen 91 and the receivers 93 .
(B) The receivers 93 are separated from each other to some extent.
(C) The distance, in the X direction and the Y direction, from the needle hole (the origin) of the needle plate 34 to the receivers 93 is large.
(D) The distance from the needle hole (the origin) to the receivers 93 is not extremely large.
(E) The receivers 93 are provided above the top surface of the bed 11 . Specifically, the receivers 94 are provided above the work cloth 100 placed on the bed 11 .
The reasons are as follows.
The condition (A) is set because if an object enters between the ultrasonic pen 91 and the receivers 93 , the receivers 93 may not receive the ultrasonic wave transmitted from the ultrasonic pen 91 . The object may be, for example, a hand or an arm of the user. For example, there is a possibility that the hand or the arm enters between the pen tip 911 and the receivers 93 when the user who holds the ultrasonic pen 91 in the user's hand is specifying the specified position. In this case, the ultrasonic wave transmitted from the ultrasonic pen 91 may be shielded by the hand or the arm. Therefore, a case may occur in which the receivers 93 cannot receive the ultrasonic wave. For that reason, it is preferable that the receivers 93 be provided in positions where the hand or the arm of the user does not enter between the ultrasonic pen 91 and the receivers 93 when the user is performing an operation using the ultrasonic pen 91 .
The reason for setting the condition (B) is as follows. When the simultaneous equations represented by Formulas (5) and (6) are solved, if the difference between the coordinates B and C is small, the results of Formulas (5) and (6) are close to each other. In this case, an error of the calculated specified coordinates E may become large.
The reason for setting the condition (C) is as follows. As the distance from the origin to the receivers 93 in the X direction and the Y direction increases, the Z-coordinate values of the coordinates B and C become relatively smaller than the X-coordinate values and the Y-coordinate values of the coordinates B and C. Therefore, it is possible to reduce an influence on a calculation result caused by the thickness of the work cloth 100 .
The reason for setting the condition (D) is as follows. If the distance from the origin to the receivers 93 is extremely large, the ultrasonic wave transmitted from the ultrasonic pen 91 may be attenuated before the ultrasonic wave reaches the receivers 93 . Therefore, it is difficult for the receivers 93 to accurately receive the ultrasonic wave.
The reason for setting the condition (E) is that the pen tip 911 of the ultrasonic pen 91 may come into contact with the top surface of the work cloth 100 that is placed on the bed 11 . It is preferable that the receivers 93 can accurately receive the ultrasonic wave transmitted from the ultrasonic pen 91 that is in contact with the top surface of the work cloth 100 , Therefore, it is preferable that the receivers 93 be provided above the top surface of the bed 11 .
In the first embodiment, as shown in FIG. 1 , the receiver 94 is provided at the lower left end of the head 14 and the receiver 95 is provided at the lower right end of the head 14 . The position on the work cloth 100 that can be easily specified by the user while the user is holding the ultrasonic pen 91 in the user's hand may be a position on the front side with respect to the needle hole. Thus, the condition (A) is substantially satisfied. The distance between the receivers 94 and 95 is almost the same as the length of the head 14 in the left-right direction. Therefore, the receivers 94 and 95 are sufficiently separated from each other, and the condition (B) is satisfied. The receivers 94 and 95 are provided on the rear side of the lower surface of the head 14 . Thus, the distances from the origin to the receivers 94 and 95 in the X direction and the Y direction are larger than when the receivers 94 and 95 are provided substantially in the center, in the front-rear direction, of the lower surface of the head 14 . Thus, the condition (C) is satisfied. The distances from the origin to the receivers 94 and 95 are not extremely large. Thus, the condition (D) is satisfied. The receivers 94 and 95 are provided above the top surface of the bed 11 . Thus, the condition (E) is satisfied. In this manner, in the first embodiment, the positions in which the receivers 94 and 95 are provided satisfy all the conditions (A) to (E). Therefore, the sewing machine 1 can calculate the specified coordinates E more precisely.
Processing that is performed by the CPU 61 of the sewing machine 1 to identify the specified position will be specifically explained with reference to FIG. 7 . Main processing is performed by the CPU 61 in accordance with the program stored in the ROM 62 . For example, when a command to perform sewing is input by a panel operation, the CPU 61 may start the main processing.
The CPU 61 determines whether an electrical signal output from the signal output circuit 914 of the ultrasonic pen 91 has been detected via the cable 912 (step S 11 ). If the electrical signal has not been detected (NO at step S 11 ), the processing returns to step S 11 . It is assumed that the user specifies an arbitrary position on the work cloth 100 using the ultrasonic pen 91 and the pen tip 911 of the ultrasonic pen 91 comes into contact with the work cloth 100 . The pen tip 911 of the ultrasonic pen 91 may be inserted into the pen body 910 and the switch 913 may be turned on. The signal output circuit 914 may output an electrical signal. The CPU 61 may detect the electrical signal (YES at step S 11 ). In a case where the switch 913 of the ultrasonic pen 91 is turned on, the ultrasonic transmitter 915 transmits an ultrasonic wave at the same time as when the signal output circuit 914 outputs the electrical signal. However, the propagation speed of the electrical signal is significantly higher than the propagation speed of the ultrasonic wave, and the electrical signal reaches the CPU 61 substantially at the same timing as the timing at which the switch 913 is turned on.
If the CPU 61 has detected the electrical signal output from the signal output circuit 914 of the ultrasonic pen 91 (YES at step S 11 ), the CPU 61 identifies a time at which the electrical signal is detected. The CPU 61 acquires the identified time as the transmission timing T 1 of the ultrasonic wave (step S 13 ). The CPU 61 stores the acquired transmission timing T 1 in the RAM 63 .
The CPU 61 determines whether the ultrasonic wave transmitted from the ultrasonic pen 91 has been detected via at least one of the receivers 94 and 95 (step S 15 ). If the ultrasonic wave has not been detected via at least one of the receivers 94 and 95 (NO at step S 15 ), the CPU 61 determines whether or not a predetermined time period (for example, one second) has elapsed (step S 35 ). If the predetermined time period has not elapsed (NO at step S 35 ), the processing returns to step S 15 . The CPU 61 stands by for the predetermined time period until at least one of the receivers 94 and 95 detect the ultrasonic wave.
Here, it is assumed that the ultrasonic wave transmitted from the ultrasonic transmitter 915 of the ultrasonic pen 91 is shielded by, for example, the hand or the arm of the user, the work cloth 100 , or the like and does not reach the receivers 94 and 95 . In this manner, if the predetermined time period has elapsed without detecting the ultrasonic wave by at least one of the receivers 94 and 95 (YES at step S 35 ), the CPU 61 displays on the LCD 15 an error message indicating that the ultrasonic wave has not been detected (step S 37 ). In a case where the user sees the error message, the user may once again specify an arbitrary position on the work cloth 100 using the ultrasonic pen 91 . The processing returns to step S 11 to re-detect the electrical signal output from the signal output circuit 914 of the ultrasonic pen 91 .
If the CPU 61 detects the ultrasonic wave via at least one of the receivers 94 and 95 within the predetermined time period from the detection of the electrical signal (YES at step S 15 ), the CPU 61 identifies a time at which the ultrasonic wave is detected. The CPU 61 acquires the identified time as the detection timing T 2 (step S 17 ). The CPU 61 stores the acquired detection timing T 2 in the RAM 63 .
The CPU 61 determines whether both the receivers 94 and 95 have detected the ultrasonic wave (step S 19 ). If one of the receivers 94 and 95 has not detected the ultrasonic wave (NO at step S 19 ), the processing returns to step S 15 . If both the receivers 94 and 95 have detected the ultrasonic wave (YES at step S 19 ), the CPU 61 calculates the propagation time Tb and the propagation time Tc (step S 21 ). The CPU 61 calculates the propagation time Tb and the propagation time Tc by subtracting the transmission timing T 1 from the detection timing T 2 .
The CPU 61 multiplies the calculated Tb and Tc by the sonic velocity V and thereby calculates the distances EB and EC (step S 23 ) (refer to Formulas (3) and (4)). The CPU 61 substitutes the coordinates B (Xb, Yb, Zb), the coordinates C (Xc, Ye, Ze), and the distances EB and EC into Formulas (5) and (6), and solves the simultaneous equations. Thus, the CPU 61 calculates the specified coordinates E (Xe, Ye, Ze (=0)). In this manner, the CPU 61 identifies the position specified using the ultrasonic pen 91 , namely, the specified position (step S 25 ).
The CPU 61 displays, on the LCD 15 , a display image that shows a relationship between the specified position, which is indicated by the specified coordinates E (Xe, Ye, Ze), and the work cloth 100 (step S 27 ). The CPU 61 determines whether the start/stop switch, which is one of the operation switches 21 , has been pressed (step S 29 ). If the start/stop switch has not been pressed (NO at step S 29 ), the processing returns to step S 29 . If the start/stop switch has been pressed (YES at step S 29 ), the CPU 61 drives the feed dog and moves the work cloth such that the position indicated by the X-coordinate “Xe” and the Y-coordinate “Ye” of the specified coordinates E calculated at step S 25 matches the needle drop point (step S 31 ). Then, the CPU 61 starts sewing (step S 33 ). In this manner, sewing is started from the position on the work cloth 100 specified using the ultrasonic pen 91 , namely, the specified position. When the sewing is complete, the main processing ends. The needle drop point is a point at which the sewing needle may penetrate the work cloth 100 , namely, the center point of the needle hole formed in the needle plate 34 .
As explained above, in a case where the user specifies an arbitrary position on the work cloth 100 using the ultrasonic pen 91 , the sewing machine 1 can identify the specified position and start sewing. In this manner, the user can easily and appropriately specify a position on the work cloth 100 using the ultrasonic pen 91 . The sewing machine 1 can detect the ultrasonic wave using the plurality of receivers 94 and 95 , and calculate the specified coordinates E based on the transmission timing T 1 and the detection timings T 2 . Thus, the sewing machine 1 can accurately identify the specified position.
The present disclosure is not limited to the first embodiment and various modifications may be made. The positions in which the receivers 94 and 95 are provided are not limited to the head 14 of the sewing machine 1 . For example, the receivers 94 and 95 may be provided on at least one of the presser foot 30 and the presser bar 31 . More specifically, the receiver 94 may be provided on the left side of the presser foot 30 or the presser bar 31 and the receiver 95 may be provided on the right side of the presser foot 30 or the presser bar 31 .
For example, the receiver 94 may be provided on one of the head 14 , the presser foot 30 , and the presser bar 31 , and the receiver 95 may be provided on the arm portion 13 side of the pillar 12 , namely, on any part of a left surface 17 (refer to FIG. 1 ) of the pillar 12 . In this case, the opening 941 of the receiver 95 is provided such that the opening 941 faces to the left. In this case, the distance between the receivers 94 and 95 is larger than when the receiver 95 is provided on the head 14 (refer to condition (B)). The distance, in the X direction and the Y direction, from the needle hole (the origin) of the needle plate 34 to the receiver 95 also increases (refer to condition (C)). Further, the receivers 94 and 95 are provided above the top surface of the bed 11 (refer to condition (E)). In this manner, the positions in which the receivers 94 and 95 are provided satisfy a plurality of conditions included in the conditions (A) to (E), in a similar manner to the first embodiment. Therefore, the sewing machine 1 can precisely calculate the specified coordinates E. Further, particularly in this case, it is possible to increase the distance between the receivers 94 and 95 .
The combinations of the positions of the receivers 94 and 95 are not limited to those of the first embodiment and the modified examples described above. In a case where the receivers 94 and 95 are provided on the head 14 , the positions of the receivers 94 and 95 are not limited to the rear side of the lower surface of the head 14 . For example, the receivers 94 and 95 may be provided on the front side of the lower surface of the head 14 , substantially in the center in the front-rear direction of the lower surface of the head 14 , or the like. In a case where the receiver 95 is provided on the left surface 17 of the pillar 12 , the height at which the receiver 95 is disposed is not particularly limited. However, it is preferable that the receiver 95 be disposed in a lower position in order to reduce an influence caused by approximating the value Ze in Formulas (5) and (6) to zero.
The receivers 94 and 95 may be provided on a part other than the head 14 , the presser foot 30 , the presser bar 31 , and the left surface 17 of the pillar 12 . For example, the receivers 94 and 95 may be provided on a lower side surface of the arm 13 , a front surface or a rear surface of the head 14 , or an upper surface of the bed 11 at the left end of the bed 11 . The ultrasonic pen 91 need not necessarily be attached to the sewing machine 1 . The sewing machine 1 may detect an ultrasonic wave output from a known device configured to output an ultrasonic wave, and may identify a position of the transmission source of the ultrasonic wave as the specified position.
Second Embodiment
A second embodiment will be explained. In the second embodiment, as shown in FIG. 8 to FIG. 10 , receivers 84 and 85 are provided not on the sewing machine 1 , but on an embroidery unit 2 , which can be attached to and detached from the bed 11 of the sewing machine 1 . FIG. 9 and FIG. 10 show the embroidery unit 2 that is not attached to the sewing machine 1 . The embroidery unit 2 includes a body portion 51 and a carriage 52 .
As shown in FIG. 9 and FIG. 10 , a connection portion 54 is provided on a right surface of the body portion 51 of the embroidery unit 2 . In a state in which the embroidery unit 2 is attached to the sewing machine 1 , the connection portion 54 is connected to a connection receiving portion (not shown in the drawings) of the sewing machine 1 , and thus the embroidery unit 2 and the sewing machine 1 are electrically connected.
The carriage 52 is provided on the upper side of the body portion 51 . The carriage 52 has a rectangular parallelepiped shape that is long in the front-rear direction. The carriage 52 includes a frame holder 55 , a Y axis movement mechanism (not shown in the drawings), and a Y axis motor (not shown in the drawings). The frame holder 55 is a holder to which an embroidery frame (not shown in the drawings) can be detachably attached. The holder 55 is provided on a right surface of the carriage 52 . The embroidery frame is a known frame that includes an inner frame and an outer frame. The embroidery frame may clamp and hold the work cloth 100 . The work cloth 100 held by the embroidery frame may be arranged on the top surface of the bed 11 and below the needle bar 29 and the presser foot 30 . The Y axis movement mechanism may move the frame holder 55 in the front-rear direction (the Y direction). Along with the movement of the frame holder 55 in the front-rear direction, the work cloth 100 held by the embroidery frame may be moved in the front-rear direction. The Y axis motor may drive the Y axis movement mechanism. The CPU 61 (refer to FIG. 5 ) controls the Y axis motor.
An X axis movement mechanism (not shown in the drawings) and an X axis motor (not shown in the drawings) are provided inside the body portion 51 . The X axis movement mechanism may move the carriage 52 in the left-right direction (the X direction). Along with the movement of the carriage 52 in the left-right direction, the work cloth 100 held by the embroidery frame may be moved in the left-right direction. The X axis motor may drive the X axis movement mechanism. The CPU 61 controls the X axis motor.
The receiver 84 is provided at the front end of an upper surface of the carriage 52 . The receiver 85 is provided at the rear end of the upper surface of the carriage 52 . The receivers 84 and 85 receive are configured to an ultrasonic wave. The receivers 84 and 85 have the same configuration as the receivers 94 and 95 . The embroidery frame attached to the frame holder 55 is located at the right of the right surface of the carriage 52 , Therefore, the receivers 84 and 85 are located above the position of the carriage 52 where the embroidery frame can be attached. Thus, the receivers 84 and 85 are located above the body portion 51 of the embroidery unit 2 . When the embroidery unit 2 is attached to the bed 11 of the sewing machine 1 , the receivers 84 and 85 are located above the bed 11 . Openings of the receivers 84 and 85 are directed to the right. In a case where the receivers 84 and 85 receive an ultrasonic wave, the receivers 84 and 85 each transmit an electrical signal to the sewing machine 1 . The CPU 61 may receive the electrical signals from the receivers 84 and 85 , and thereby may detect the ultrasonic wave transmitted from the ultrasonic pen 91 .
Processing that is performed by the CPU 61 of the sewing machine 1 to identify the specified position will be explained with reference to FIG. 7 . In a case where the CPU 61 detects an electrical signal output from the signal output circuit 914 of the ultrasonic pen 91 via the cable 912 (YES at step S 11 ), the CPU 61 acquires the transmission timing T 1 (step S 13 ). In a case where the CPU 61 receives the electrical signal from each of the receivers 84 and 85 (YES at step S 15 ), the CPU 61 identifies a time at which the electrical signal is received from the receiver 84 and a time at which the electrical signal is received from the receiver 85 , and acquires the identified times as the detection timings T 2 (step S 17 ). The CPU 61 calculates the specified coordinates E and identifies the specified position (steps S 21 to S 25 ). The CPU 61 controls the X axis motor and the Y axis motor, and thereby moves the embroidery frame such that the position of the specified coordinates E on the work cloth 100 matches the needle drop point (step S 31 ). Next, the CPU 61 starts sewing on the work cloth 100 . The CPU 61 drives the needle bar 29 and the shuttle mechanism (not shown in the drawings) simultaneously with the embroidery frame being moved in the left-right direction (the X direction) and the front-rear direction (the Y direction). The sewing needle attached on the needle bar 29 sews an embroidery pattern on the work cloth 100 held by the embroidery frame. In this manner, the embroidery pattern is sewn in the specified position on the work cloth 100 (step S 33 ).
In the second embodiment, the receivers 84 and 85 are respectively provided at the front end and the rear end of the carriage 52 , as shown in FIG. 9 and FIG. 10 . Therefore, when the embroidery unit 2 is attached to the bed 11 , all the above-described conditions (A) to (E) are satisfied. The ultrasonic wave transmitted from the ultrasonic pen 91 when the pen tip 911 is in contact with the work cloth 100 may be not shielded by the hand or the arm of the user (refer to condition (A)). The distance between the receivers 84 and 85 is separated by a length, in the front-rear direction, of the carriage 52 . As a result, the receivers 84 and 85 are sufficiently separated from each other (refer to condition (B)). The distances, in the X direction and the Y direction, from the needle hole (the origin) of the needle plate 34 to the receivers 84 and 85 are larger than when the receivers 84 and 85 are provided on the head 14 , the presser foot 30 or the presser bar 31 of the sewing machine 1 (refer to condition (C)). The distances from the origin to the receivers 84 and 85 are not extremely large (refer to condition (D)). The receivers 84 and 85 are provided above the body portion 51 of the embroidery unit 2 . Therefore, the receivers 84 and 85 are located above the bed 11 (refer to condition (E)). Specifically, the receivers 84 and 85 are provided above the work cloth 100 held by the embroidery frame. Therefore, the sewing machine 1 can calculate the specified coordinates E more precisely and perform sewing on the work cloth 100 . Further, the height from the top surface of the bed 11 to the receivers 84 and 85 is low. If the height from the top surface of the bed 11 to the receivers 84 and 85 is high, there is a possibility that the influence on a calculation result caused by the thickness of the work cloth 100 increases. If the height from the top surface of the bed 11 to the receivers 84 and 85 is low, the influence caused by approximating the value Ze in Formulas (5) and (6) to zero may decrease. Therefore, the error of the calculated specified coordinates E may become small.
In the second embodiment, the receivers 84 and 85 may be provided on a part other than the top surface of the carriage 52 . For example, the receiver 84 may be provided on a front surface of the carriage 52 and the receiver 85 may be provided on a rear surface of the carriage 52 . For example, the receiver 84 may be provided at the front side of the right surface of the carriage 52 , and the receiver 85 may be provided at the rear side of the right surface of the carriage 52 .
Third Embodiment
A third embodiment will be explained. As shown in FIG. 11 , the sewing machine 1 of the third embodiment is different from the sewing machine 1 of the first embodiment in that the sewing machine 1 is provided with an ultrasonic pen 92 that is not connected to the sewing machine 1 via a cable. Instead of the signal output circuit 914 (refer to FIG. 5 ), an electromagnetic wave output circuit 921 (refer to FIG. 12 ) is provided inside the ultrasonic pen 92 . The ultrasonic pen 92 accommodates a battery (not shown in the drawings). The ultrasonic pen 92 may be driven by the battery. The electromagnetic wave output circuit 921 may output an electromagnetic wave signal of a predetermined frequency. When the switch 913 (refer to FIG. 12 ) is in an OFF state, the electromagnetic circuit 921 does not output the electromagnetic wave signal. When the switch 913 is turned on, the electromagnetic wave output circuit 921 outputs the electromagnetic wave signal. The CPU 61 may receive the electromagnetic wave signal output from the electromagnetic wave output circuit 921 using an electromagnetic wave detector 97 (refer to FIG. 12 ). The electromagnetic wave detector 97 is provided inside the sewing machine 1 . The position of the electromagnetic detector 97 is not limited to the inside of the sewing machine 1 as long as the sewing machine 1 can receive the electromagnetic wave signal.
An electrical configuration of the sewing machine 1 and the ultrasonic pen 92 according to the third embodiment will be explained with reference to FIG. 12 . The third embodiment is different from the first embodiment in that the ultrasonic pen 92 includes the electromagnetic wave output circuit 921 and in that the sewing machine 1 includes the electromagnetic wave detector 97 . The electromagnetic wave output circuit 921 is connected to the switch 913 . The electromagnetic detector 97 is connected to the input/output interface 65 . When the electromagnetic wave detector 97 receives the electromagnetic wave signal output from the electromagnetic wave output circuit 921 of the ultrasonic pen 92 , the electromagnetic wave detector 97 outputs a signal to the CPU 61 via the input/output interface 65 .
Main processing according to the third embodiment will be explained with reference to FIG. 7 . At step S 11 , the CPU 61 determines whether the electromagnetic wave detector 97 has detected the electromagnetic wave signal output from the electromagnetic wave output circuit 921 of the ultrasonic pen 92 , instead of detecting the electrical signal output from the signal output circuit 914 of the ultrasonic pen 91 (step S 11 ). If the electromagnetic wave detector 97 has not detected the electromagnetic wave signal (NO at step S 11 ), the processing returns to step S 11 . If the electromagnetic wave detector 97 has detected the electromagnetic wave signal (YES at step S 11 ), the CPU 61 identifies a time at which the electromagnetic wave signal has been detected. The CPU 61 acquires the identified time as the transmission timing T 1 of the ultrasonic wave (step S 13 ). The CPU 61 stores the acquired transmission timing T 1 in the RAM 63 . Processing from steps S 15 to S 33 is performed in the same manner as in the first embodiment, and an explanation thereof is omitted here.
As explained above, in the third embodiment, the sewing machine 1 can identify the transmission timing of the ultrasonic wave by detecting the electromagnetic wave signal output by the ultrasonic pen 92 . In other words, there is no need to provide a cable to connect the ultrasonic pen 92 and the sewing machine 1 . As a result, there is no way the cable can be an obstruction to the operation. Thus, the user can easily specify the specified position on the work cloth 100 using the ultrasonic pen 92 .
In the third embodiment, the ultrasonic pen 92 may be provided with a known timer circuit and the timer circuit may be connected to the electromagnetic wave output circuit 921 . In this case, the electromagnetic wave output circuit 921 of the ultrasonic pen 92 may output an electromagnetic wave signal that notifies the CPU 61 of the time at which the switch 913 is turned on. The CPU 61 may receive the electromagnetic wave signal via the electromagnetic wave detector 97 and may identify the time notified by the electromagnetic wave signal. The CPU 61 may acquire the identified time as the transmission timing of the ultrasonic wave.
The electromagnetic wave signal output from the electromagnetic wave output circuit 921 may be an electromagnetic wave signal of an arbitrary frequency. For example, the electromagnetic wave signal may be a microwave or infrared light.
Fourth Embodiment
A fourth embodiment will be explained. As shown in FIG. 13 , the fourth embodiment is different from the third embodiment in that the sewing machine 1 is provided with a receiver 96 in addition to the receivers 94 and 95 and in that the ultrasonic pen 92 is not provided with the electromagnetic wave output circuit 921 , as will be described below in detail. The receiver 96 is provided on the left surface 17 of the pillar 12 . The receiver 96 has the same configuration as the receivers 94 and 95 . The receiver 96 is provided such that an opening (not shown in the drawings) of the receiver 96 is directed to the left. The CPU 61 may detect the ultrasonic wave using the receivers 94 , 95 and 96 and may calculate the specified coordinates E based on the detection timings T 2 of the receivers 94 , 95 and 96 . Unlike the first embodiment to the third embodiment, the CPU 61 does not acquire the transmission timing T 1 of the ultrasonic wave, and does not use the transmission timing T 1 when calculating the specified coordinates E. An electrical configuration of the sewing machine 1 according to the fourth embodiment is a configuration obtained by removing the electromagnetic wave detector 97 and the electromagnetic wave output circuit 921 from the block diagram shown in FIG. 12 that shows the electrical configuration of the sewing machine 1 according to the third embodiment.
A method for identifying a position on the work cloth 100 specified by the ultrasonic pen 92 will be explained with reference to FIG. 14 . The may user specify the specified position on the work cloth 100 by causing the pen tip 911 of the ultrasonic pen 92 to touch the work cloth 100 . The left-right direction and the up-down direction of FIG. 14 respectively correspond to the X direction and the Y direction. A direction from the near side to the far side of FIG. 14 corresponds to the Z direction. Coordinates D of the receiver 96 are denoted by (Xd, Yd, Zd). A distance between the specified coordinates E and the coordinates D of the receiver 96 is referred to as a “distance ED”.
The distance ED can be expressed by the coordinates B, C, D, and E based on the Pythagorean theorem. The distance ED and the coordinates D and E satisfy a relationship of the following Formula (7).
( Xd−Xe ) 2 +( Yd−Ye ) 2 +( Zd−Ze ) 2 =( ED ) 2 Formula (7)
In the same manner as Formulas (1) and (2) described above, Formula (7) is the same as the equation of a spherical surface (whose radius is the distance ED), the origin of which is the coordinates D and on which the specified coordinates E is.
A time required from when the ultrasonic wave is transmitted from the ultrasonic pen 92 at the specified coordinates E to when the ultrasonic wave reaches the receiver 96 is referred to as a propagation time Td. In this case, the distance ED can be expressed by the following Formula (8).
ED=V×Td Formula (8)
Further, Formulas (4) and (8) can be transformed into the following Formulas (9) and (10).
EC=V×Tc=V ×( Tc−Tb )+ V×Tb Formula (9)
ED=V×Td=V ×( Td−Tb )+ V×Tb Formula (10)
A propagation time difference (Tc−Tb) in Formula (9) is the same as the difference between the detection timing T 2 at which the ultrasonic wave is detected via the receiver 95 and the detection timing T 2 at which the ultrasonic wave is detected via the receiver 94 . In a similar manner, a propagation time difference (Td−Td) in Formula (10) is the same as the difference between the detection timing T 2 at which the ultrasonic wave is detected via the receiver 96 and the detection timing T 2 at which the ultrasonic wave is detected via the receiver 94 . Accordingly, Formulas (9) and (10) can be transformed into the following Formulas (11) and (12). Detection timings at which the ultrasonic wave is detected via the receivers 94 , 95 , and 96 irrespectively referred to as T 2 b , T 2 c and T 2 d.
EC=V ×( T 2 c−T 2 b )+ V×Tb Formula (11)
ED=V ×( T 2 d−T 2 b )+ V×Tb Formula (12)
Following Formulas (13), (14), and (15) can be obtained by substituting Formulas (3), (11), and (12) into Formulas (1), (2), and (7).
( Xb−Xe ) 2 +( Yb−Ye ) 2 +( Zb−Ze ) 2 =( V×Tb ) 2 Formula (13)
( Xc−Xe ) 2 +( Ye−Ye ) 2 +( Zc−Ze ) 2 ={V ×( T 2 c−T 2 b )+ V×Tb} 2 Formula (14)
( Xd−Xe ) 2 +( Yd−Ye ) 2 +( Zd−Ze ) 2 ={V ×( T 2 d−T 2 b )+ V×Tb} 2 Formula (15)
In Formulas (13), (14), and (15), the coordinates B (Xb, Yb, Zb), the coordinates C (Xc, Ye, Zc), the coordinates D (Xd, Yd, Zd), and the sonic velocity V are known values and are stored in advance in the ROM 62 . The detection timings T 2 b , T 2 c and T 2 d respectively correspond to times at which The CPU 61 detects the ultrasonic wave via the receivers 94 , 95 , and 96 (step S 43 , refer to FIG. 15 ). The value Ze of the specified coordinates E (Xe, Ye, Ze) is deemed to be zero. Based on the above, the values Xe, Ye, and Tb can be calculated by solving the simultaneous equations represented by Formulas (13), (14), and (15). In this manner, the specified coordinates E (Xe, Ye, Ze (=0)) on the work cloth 100 that are specified using the ultrasonic pen 92 are calculated.
Processing that is performed by the CPU 61 of the sewing machine 1 to identify the specified position will be explained with reference to FIG. 15 . The main processing is performed by the CPU 61 in accordance with the program stored in the ROM 62 . The CPU 61 may start the main processing when, for example, a command to perform sewing is input by a panel operation.
The CPU 61 determines whether at least one of the receivers 94 , 95 , and 96 has detected the ultrasonic wave transmitted from the ultrasonic pen 92 (step S 41 ). If none of the receivers 94 , 95 , and 96 has detected the ultrasonic wave (NO at step S 41 ), the CPU 61 determines whether the ultrasonic wave has been detected by at least one of the receivers 94 , 95 , and 96 after the main processing has been started (step S 61 ). If none of the receivers 94 , 95 and 96 has detected the ultrasonic wave after the main processing has been started (NO at step S 61 ), the processing returns to step S 41 . If the ultrasonic wave has been detected by at least one of the receivers 94 , 95 , and 96 after the main processing has been started (YES at step S 61 ), the CPU 61 determines whether a predetermined time period (for example, one second) has elapsed from when the ultrasonic wave has been detected for the first time after the start of the main processing (step S 63 ). If the predetermined time period has not elapsed (NO at step S 63 ), the processing returns to step S 41 . If the predetermined time period has elapsed (YES at step S 63 ), the CPU 61 displays an error message, on the LCD 15 , indicating that the ultrasonic wave has not been detected (step S 65 ). The processing returns to step S 41 .
If at least one of the receivers 94 , 95 , and 96 has detected the ultrasonic wave within the predetermined time period (YES at step S 41 ), the CPU 61 identifies a time at which the ultrasonic wave has been detected. The CPU 61 acquires the identified time as the detection timing T 2 (step S 43 ). The CPU 61 stores the acquired detection timing T 2 in the RAM 63 .
The CPU 61 determines whether all the receivers 94 , 95 , and 96 have detected the ultrasonic wave (step S 45 ). If at least one of the receivers 94 , 95 , and 96 has not detected the ultrasonic wave (NO at step S 45 ), the processing returns to step S 41 . If all the receivers 94 , 95 , and 96 have detected the ultrasonic wave (YES at step S 45 ), the CPU 61 calculates differences “T 2 c -T 2 b ” and “T 2 d -T 2 b ” between the detection timings (step S 47 ). The CPU 61 calculates the distances EB, EC, and ED based on the calculated differences and the propagation time Tb (step S 49 ) (refer to Formulas (3), (11), and (12)). The CPU 61 substitutes the coordinates B (Xb, Yb, Zb), the coordinates C (Xc, Ye, Zc), the coordinates D (Xd, Yd, Zd), and the distances EB, EC, and ED into Formulas (13), (14), and (15), and solves the simultaneous equations. Thus, the CPU 61 calculates the specified coordinates E (Xe, Ye, Ze (=0)). In this manner, the CPU 61 identifies the position specified using the ultrasonic pen 92 , namely, the specified position (step S 51 ). Processing from steps S 27 to S 33 is performed in the same manner as in the first embodiment to the third embodiment (refer to FIG. 7 ) and an explanation thereof is thus omitted here.
As explained above, in the fourth embodiment, the sewing machine 1 can calculate the specified coordinates E using only the detection timings T 2 without using the transmission timing T 1 , unlike the first embodiment to the third embodiment. Therefore, there is no need to provide structural elements that are necessary to identify the transmission timing T 1 , such as the signal output circuit 914 (refer to FIG. 5 ) in the first embodiment, or the electromagnetic wave detector 97 and the electromagnetic wave output circuit 921 in the third embodiment. As a result, in the fourth embodiment, the specified coordinates E can be calculated with a simpler configuration than the configurations of the first embodiment to the third embodiment.
In the fourth embodiment, the three positions in which the receivers 94 , 95 , and 96 are provided are not limited to the lower left end and the lower right end of the head 14 of the sewing machine 1 and the left surface 17 of the pillar 12 . For example, all the receivers 94 , 95 , and 96 may be provided on the head 14 . For example, the receiver 94 may be provided on the rear side of the lower left end of the head 14 , the receiver 95 may be provided on the rear side of the lower right end of the head 14 , and the receiver 96 may be provided at substantially the center of the front side of the lower end of the head 14 .
The receivers 94 and 95 may be provided on the left and right sides of the presser bar 31 or the presser foot 30 , and the receiver 96 may be provided on the left surface 17 of the pillar 12 . The receiver 96 may be provided on the lower surface of the arm 13 .
The receivers 94 and 95 may be provided on the left and right sides of the presser bar 31 or the presser foot 30 , and the receiver 96 may be provided at substantially the center, in the left-right direction, of the front side of the lower end of the head 14 .
As explained above, the receivers 94 , 95 , and 96 may be provided on any of the head 14 , the presser foot 30 , the presser bar 31 , the left surface 17 of the pillar 12 and the lower surface of the arm 13 . The combinations of the portions of the receivers 94 , 95 , and 96 are not limited to those of the above-described fourth embodiment and the modified examples.
In a case where the embroidery unit 2 is attached to the sewing machine 1 and used, the receivers 94 , 95 , and 96 may be provided on the carriage 52 (refer to FIG. 8 to FIG. 10 ). In this case, the receivers 94 and 95 may be respectively provided at the front end and the rear end of the top surface of the carriage 52 , and the receiver 96 may be provided at substantially the center, in the front-rear direction, of the top surface of the carriage 52 . The receivers 94 and 95 may be respectively provided at the front end and the rear end of the top surface of the carriage 52 , and the receiver 96 may be provided on the rear side of the lower right end of the head 14 . The receivers 94 and 95 may be respectively provided at the front end and the rear end of the top surface of the carriage 52 , and the receiver 96 may be provided on the left surface 17 of the pillar 12 .
Fifth Embodiment
A fifth embodiment will be explained. As shown in FIG. 16 , a multi-needle sewing machine 3 (hereinafter referred to as a sewing machine 3 ) according to the fifth embodiment includes a plurality of needle bars. The sewing machine 3 is provided with receivers 131 and 132 . A configuration of the sewing machine 3 will be explained with reference to FIG. 16 to FIG. 18 . In the explanation below, it is defined that the upper side, the lower side, the left side, the right side, the near side, and the far side of FIG. 16 are respectively defined as the upper side, the lower side, the left side, the right side, the front side, and the rear side of the sewing machine 3 . That is, the direction in which a pillar 103 , which will be described below, extends is the up-down direction of the sewing machine 3 . The direction in which an arm 104 extends is the front-rear direction of the sewing machine 3 .
As shown in FIG. 16 and FIG. 17 , a main body 120 of the sewing machine 3 includes a support portion 102 , the pillar 103 , and the arm 104 . The support portion 102 is formed in an inverted U shape in a plan view and supports the whole of the sewing machine 3 . A left and right pair of guide grooves 125 are provided on a top surface of the support portion 102 . The guide grooves 125 extend in the front-rear direction. The pillar 103 extends upward from the rear end of the support portion 102 . The arm 104 extends forward from the upper end of the pillar 103 . A needle bar case 121 is mounted on the leading end (the front end) of the arm 104 such that the needle bar case 121 can be moved in the left-right direction. Ten needle bars (not shown in the drawings) that extend in the up-down direction are provided inside the needle bar case 121 such that the needle bars are arranged at equal intervals in the left-right direction. One of the ten needle bars that is in a sewing position may be slidingly moved in the up-down direction by a needle bar drive mechanism (not shown in the drawings) that is provided inside the needle bar case 121 . A sewing needle 135 can be attached to and detached from the lower end of each of the needle bars.
An operation portion 106 is provided on the right side of a central portion, in the front-rear direction, of the arm 104 . The operation portion 106 includes a liquid crystal display (LCD) 107 , a touch panel 108 , and an operation switch 141 . The LCD 107 may display various types of information, such as an operation image that is used for the user to input a command, for example. The touch panel 108 is used to accept a command from the user. The user may perform an operation of pressing the touch panel 108 using a finger or a dedicated touch pen. Hereinafter, this operation is referred to as a “panel operation”. The touch panel 108 detects a position pressed by the finger, the dedicated touch pen, or the like, and the sewing machine 3 determines the item that corresponds to the detected position. In this manner, the sewing machine 3 recognizes the selected item. By the panel operation, the user can select or set a pattern to be sewn and various types of conditions, such as sewing conditions. The operation switch 141 is used to command the start or stop of the sewing.
A cylinder bed 110 is provided below the arm 104 . The cylinder bed 110 extends forward from the lower end of the pillar 103 . A shuttle (not shown in the drawings) is provided inside the leading end (the front end) of the cylinder bed 110 . The shuttle may house a bobbin (not shown in the drawings) around which a lower thread (not shown in the drawings) is wound. A shuttle mechanism (not shown in the drawings) is provided inside the cylinder bed 110 . The shuttle mechanism (not shown in the drawings) may drive the shuttle. A needle plate 116 , which has a rectangular shape in a plan view, is provided on a top surface of the cylinder bed 110 . A needle hole (not shown in the drawings), through which the sewing needle 135 may pass, is formed in the needle plate 116 .
A left and right pair of thread spool stands 112 are provided at the rear side of a top surface of the arm 104 . Ten thread spools (not shown in the drawings), the number of which is the same as the number of the needle bars, can be placed on the pair of thread spool stands 112 . A upper thread (not shown in the drawings) may be supplied from a thread spool placed on one of the thread spool stands 112 . The upper thread may be supplied to an eye (not shown in the drawings) of the sewing needle 135 that is attached to the lower end of each of the needle bars, via a thread guide 117 , a tensioner 118 , a thread take-up lever 119 , and the like. The ultrasonic pen 91 may be connected to the sewing machine 3 via the cable 912 , in the same manner as in the first embodiment.
An embroidery frame movement mechanism 111 (refer to FIG. 18 ) is provided below the arm 104 . The embroidery frame movement mechanism 111 may detachably support an embroidery frame 184 (refer to FIG. 18 ). Various types of embroidery frames can be used as the embroidery frame 184 . The embroidery frame 184 may hold the work cloth 100 . The embroidery frame movement mechanism 111 may be driven by an X axis motor (not shown in the drawings) and a Y axis motor (not shown in the drawings), and may move the embroidery frame 184 in the front-rear direction and in the left-right direction.
The embroidery frame movement mechanism 111 will be explained with reference to FIG. 18 . The embroidery frame movement mechanism 111 includes a holder 124 , an X carriage 122 , an X axis drive mechanism (not shown in the drawings), a Y carriage 123 , and a Y axis movement mechanism (not shown in the drawings). The holder 124 may detachably support the embroidery frame 184 . The X carriage 122 is a plate member that is long in the left-right direction. A part of the X carriage 122 protrudes forward from the front face of the Y carriage 123 . The holder 124 is attached to the X carriage 122 . The X carriage 122 may move in the left-right direction (the X axis direction) using the X axis motor as a driving source.
The Y carriage 123 has a box shape that is long in the left-right direction. The Y carriage 123 supports the X carriage 122 such that the X carriage 122 can be moved in the left-right direction. The Y axis movement mechanism (not shown in the drawings) is provided with a left and right pair of moving members (not shown in the drawings). The moving members are coupled to lower portions of the left and right ends of the Y carriage 123 . The moving members pass through the guide grooves 125 (refer to FIG. 16 ) in the up-down direction. The moving members may be moved in the front-rear direction (the Y axis direction) along the guide grooves 125 , using the Y axis motor as a driving source. The Y carriage 123 coupled to the moving members and the X carriage 122 supported by the Y carriage 123 may be moved in the front-rear direction (the Y axis direction) along with the movement of the moving members. In a state in which the embroidery frame 184 that holds the work cloth 100 is attached to the holder 124 , the work cloth 100 is arranged between one of the needle bars and the needle plate 116 .
As shown in FIG. 16 to FIG. 18 , the receiver 131 is provided at the left end of a top surface of the Y carriage 123 , and the receiver 132 is provided at the right end of the top surface of the Y carriage 123 . The receivers 131 and 132 are configured to receive an ultrasonic wave. The receivers 131 and 132 have the same configuration as the receiver 94 . The embroidery frame 184 attached to the folder 124 is located at the front of the Y carriage 123 . Therefore, the receivers 131 and 132 are located above the work cloth 100 held by the embroidery frame 184 . Openings provided in the receivers 131 and 132 are directed forward.
Processing that is performed by a CPU (not shown in the drawings) of the sewing machine 3 to identify the specified position will be briefly explained with reference to FIG. 7 . In a case where the CPU detects an electrical signal output from the signal output circuit 914 of the ultrasonic pen 91 via the cable 912 (YES at step S 11 ), the CPU acquires the transmission timing T 1 (step S 13 ). In a case where the CPU detects the ultrasonic wave transmitted from the ultrasonic pen 91 via the receivers 131 and 132 (YES at step S 15 ), the CPU identifies a time at which the ultrasonic wave is detected by the receiver 131 and a time at which the ultrasonic wave is detected by the receiver 132 , and acquires the identified times as the detection timings T 2 (step S 17 ). The CPU calculates the specified coordinates E and identifies the specified position (steps S 21 to S 25 ), In a case where a panel operation is performed to start sewing (YES at step S 29 ), the CPU controls the X axis motor and the Y axis motor and thereby moves the embroidery frame 184 such that the position of the specified coordinates E on the work cloth 100 matches a needle drop point (step S 31 ). The CPU starts sewing on the work cloth 100 . The CPU drives the needle bar and the shuttle mechanism simultaneously with the embroidery frame being moved in the left-right direction (the X direction) and the front-rear direction (the Y direction). The sewing needle attached to the needle bar sews an embroidery pattern on the work cloth 100 held by the embroidery frame. In this manner, the embroidery pattern is sewn in the specified position on the work cloth 100 (step S 33 ).
The receivers 131 and 132 are provided on the Y carriage 123 . Therefore, the ultrasonic wave that is transmitted from the ultrasonic pen 91 when the pen tip 911 is in contact with the work cloth 100 is unlikely to be shielded by a hand or an arm of the user who uses the ultrasonic pen 91 (refer to condition (A)). The distance between the receivers 131 and 132 is separated by a length, in the left-right direction, of the Y carriage 123 . Therefore, the receivers 131 and 132 are sufficiently separated from each other (refer to condition (B)). The distances, in the X direction and the Y direction, from the needle hole (the origin) of the needle plate 116 to the receivers 131 and 132 are large (refer to condition (C)). The distances between the origin and the receivers 131 and 132 are not extremely large (refer to condition (D)). The receivers 131 and 132 are provided above the cylinder bed 110 (refer to condition (E)).
As described above, in the fifth embodiment, the sewing machine 3 is provided with the receivers 131 and 132 . The sewing machine 3 can identify the specified position by detecting the ultrasonic wave by each of the receivers 131 and 132 . The positions in which the receivers 131 and 132 are provided satisfy all the above-described conditions (A) to (E). Therefore, the sewing machine 3 can calculate the specified coordinates E more precisely and can perform sewing on the work cloth 100 . Further, the height from the cylinder bed 110 to the receivers 131 and 132 is sufficiently small. As a result, the influence caused by approximating the value Ze in Formulas (5) and (6) to zero may decrease. Therefore, the error of the calculated specified coordinates E may become small.
In the above-described fifth embodiment, the sewing machine 3 may be provided with the ultrasonic pen 92 that may output an electromagnetic wave signal, instead of the ultrasonic pen 91 . The receivers 131 and 132 may be provided in positions other than the Y carriage 123 . For example, the receivers 131 and 132 may be provided on a front surface of the pillar 103 and a lower surface of the arm 104 .
The sewing machine 3 may be provided with three receivers as in the fourth embodiment. The sewing machine 3 may identify the specified position based only on the detection timings. In this case, the receivers may be provided on any positions on the sewing machine 3 , without being limited to the Y carriage 123 . For example, the receivers may be provided on the front surface of the pillar 103 and the lower surface of the arm 104 .
Sixth Embodiment
The number of the receivers may be one. For example, it is assumed that the one receiver is the receiver 94 that is provided on the left lower end of the head 14 . Then, with respect to the coordinates B indicating the position of the receiver 94 , specified coordinates indicating the specified position specified by the ultrasonic pen 91 are referred to as coordinates F. At this time, the X coordinates of the coordinates B and the coordinates F are assumed to be the same. To simplify an explanation, Z coordinates are omitted in the following explanation. In other words, the coordinates B are assumed to be (Xb, Yb) and the coordinates F are assumed to be (Xb, Yf). In this case, it is possible to calculate a distance FB between the coordinates F and the coordinates B in the Y direction, based on the propagation time required for the ultrasonic wave transmitted from the ultrasonic pen 91 that is at the coordinates F of the specified position to reach the receiver 94 . The coordinates B are known values. Thus, with respect to the needle drop point that is the origin, the Y coordinate “Yf” of the coordinates F of the specified position can be calculated.
The apparatus and methods described above with reference to the various embodiments are merely examples. It goes without saying that they are not confined to the depicted embodiments. While various features have been described in conjunction with the examples outlined above, various alternatives, modifications, variations, and/or improvements of those features and/or examples may be possible. Accordingly, the examples, as set forth above, are intended to be illustrative. Various changes may be made without departing from the broad spirit and scope of the underlying principles. | A sewing machine includes at least one detecting portion, a processor, and a memory. The at least one detecting portion is configured to detect an ultrasonic wave that has been transmitted from a transmission source. The memory is configured to store computer-readable instructions that instruct the sewing machine to execute steps including identifying a position of the transmission source of the ultrasonic wave based on information pertaining to the ultrasonic wave that has been detected by the at least one detecting portion, and controlling sewing based on the position of the transmission source that has been identified. | 3 |
ClAIM OF PRIORITY
This application claims priority to, and incorporates by reference herein in its entirety, pending U.S. Provisional Patent Application Ser. No. 60/693,158, filed Jun. 23, 2005, and entitled “Multi-Band Hybrid SOA-Raman Amplifier for CWDM.”
FIELD OF THE INVENTION
The present invention relates generally to transporting multiple wavelength channels on a single optical fiber over moderate distances and, more particularly, to a multiband hybrid amplifier for use in coarse wavelength division multplexing transmission systems.
BACKGROUND OF THE INVENTION
Coarse wavelength division multiplexing (CWDM) has recently emerged as an inexpensive technology for transporting multiple wavelength channels on a single optical fiber over moderate distances. CWDM's low cost relative to dense wavelength division multiplexing (DWDM) is attributed to the fact that the CWDM spectrum is orders of magnitude sparser than a typical DWDM spectrum. The ITU standard for CWDM defines a maximum of 18 wavelength channels with a channel-to-channel wavelength separation of 20 nm. That large channel spacing permits a 13-nm channel bandwidth, which in turn makes possible the use of inexpensive CWDM optics and directly modulated, un-cooled semiconductor laser transmitters. In contrast, DWDM systems, with typical channel spacings of 0.8 or 0.4 mm, require tightly specified and controlled laser transmitters, since the laser wavelength must fall within a small fraction of a nanometer over the entire life of the laser (typically ±0.1 nm for a system with 0.8-nm channel spacing). Their relatively small channel counts make CWDM systems the natural choice for transporting wavelengths at the edge of the network, where traffic is not highly aggregated as it is in the network core.
CWDM is considered an un-amplified technology since the large wavelength spread occupied by all channels in a typical commercial CWDM system (73 nm for a 4-channel system, 153 nm for an 8-channel system) cannot be accommodated by readily available low cost optical amplifiers. For example, inexpensive erbium-doped fiber amplifiers have an optical bandwidth of only about 30 nm. Being an un-amplified technology limits the reach of most commercial CWDM systems to approximately 80 km. That constraint could be overcome with the invention of a low-cost, broadband optical amplifier.
Although, in practice, semiconductor optical amplifiers (SOA) are capable of amplifying as many as 4 CWDM channels per SOA, the trade-off between maintaining sufficient optical signal-to-noise ration (OSNR) and reducing gain saturation induced crosstalk reduces the dynamic range of pure SOA solutions while rendering them inadequate for systems with cascaded amplifiers.
Raman amplifiers have been tried in this application. A Raman amplifier is based on the nonlinear optical interaction between the optical signal and a high power pump laser. The gain medium may be the existing optical fiber or may be a custom highly non-linear fiber. A recently disclosed all-Raman amplifier covering the commercially-standard 8 CWDM channel wavelengths exhibited approximately 10 dB lower gain yet required 7 Raman pumps with widely varying pump powers, a total launched power over 1100 mW, and a custom highly nonlinear fiber (HNLF) gain medium.
Several fiber network providers are currently either evaluating or deploying CWDM systems to reduce costs. All those who deploy CWDM will have situations that require extending reach. With present technology, their only solution will be to install an expensive regenerator to perform the following steps: 1) optically demultiplex the CWDM channels; 2) convert each optical channel to analog electrical signals; 3) amplify the analog electrical signals; 4) recover the system clock; 5) use a decision circuit to regenerate a re-timed digital electrical data stream from the analog data and the recovered system clock; 6) use this electrical data to drive a CWDM laser transmitter for each channel; and 7) multiplex the various CWDM wavelengths onto the common transmission fiber. All of those (steps 1-7) could be replaced by a single low-cost optical amplifier.
There remains a need for a cost-effective amplifier that is useful with commercially-available CWDM systems, while minimizing the above-described disadvantages.
SUMMARY OF THE INVENTION
The present invention addresses the needs described above by providing a method and system for amplifying an optical signal. In one embodiment of the invention, a data transport system is provided. The system includes an optical fiber cable, at least one coarse wavelength division multiplexer (CWDM) for transmitting an optical signal on the fiber within plurality of signal channels in a wavelength range, at least one Raman pump having a pumping wavelength outside any signal channel, coupled to the fiber to amplify the signal, and at least one semiconductor optical amplifier (SOA) having a gain over at least one of the signal channels, connected to the fiber to amplify the signal.
A gain of the at least one Raman pump may increase as a function of wavelength within the wavelength range, and the gain of the at least one SOA may decrease within the wavelength range. The sum of those gains may be more constant over the wavelength range than the individual gains.
The at least one Raman pump may comprise a plurality of Raman pumps, outputs of which are multiplexed by a pump multiplexer. The output of the pump multiplexer may be coupled onto the optical fiber cable via an optical circulator.
Another embodiment of the invention is a hybrid optical amplifier for amplifying an optical signal. The optical signal is transmitted on an optical fiber and has a frequency range. The amplifier includes at least one Raman pump coupled to the fiber, having a gain within the frequency range and creating a Raman amplified signal. The hybrid amplifier further includes a band demultiplexer for splitting the Raman amplified signal propagating in the fiber into a plurality of band signals having band frequency ranges, at least one semiconductor optical amplifier (SOA), each said SOA connected for amplifying a band signal of the plurality of band signals, and having a gain within the band frequency range of the band signal, and a band multiplexer for recombining the band signals after amplification.
In that embodiment of the hybrid amplifier, the at least one Raman pump may comprise three Raman pumps, outputs of which are multiplexed by a pump multiplexer. An output of the pump multiplexer may be coupled onto the optical fiber cable via an optical circulator.
The optical signal may comprise a plurality of wavelength bands, in which case a summed gain of the Raman pumps increases monotonically across each wavelength band.
The optical signal may include at least two frequency channels having a null frequency range between the channels, and at least one of the Raman pumps in that case may include a pump laser having a frequency within the null frequency range.
The Raman pumps may include a first pump laser having emission wavelength 1365 nm and optical power coupled into the Raman gain medium 200 mW, a second pump having emission wavelength 1430 nm and optical power coupled into the Raman gain medium 250 mW, and a third pump having emission wavelength 1500 nm and optical power coupled into the Raman gain medium 150 mW.
The at least one SOA may comprise a plurality of SOAs, one connected for amplifying each band signal. The optical signal may comprise at least two frequency bands, wherein the at least one SOA comprises a single SOA amplifying a first of said frequency bands, and a second of said frequency bands is not amplified by an SOA. The optical signal may comprise an 8-channel spectrum, and wherein the band demultiplexer may split the spectrum into two 4-channel bands.
Yet another embodiment of the invention is a method for amplifying a CWDM optical signal having at least first and second frequency bands. The method includes the steps of amplifying the CWDM optical signal using at least one Raman pump coupled to the optical fiber cable, splitting the amplified CWDM optical signal into the at least two frequency bands, further amplifying at least one of the frequency bands using a semiconductor optical amplifier (SOA), and recombining the at least two frequency bands.
The at least one Raman pump may comprise a plurality of pump lasers, each having a different wavelength. The bands of the CWDM optical signal may comprise channels having null frequency ranges between them, in which case a wavelength of at least one of the plurality of pump lasers may be within the null frequency.
A net gain of the Raman amplifying step and the SOA amplifying step may be flat over the CWDM frequency range to within 5 dB. The CWDM optical signal may comprise an 8-channel spectrum split into two 4-channel bands, and each band may be separately amplified by an SOA. A wavelength spread occupied by the CWDM optical signal may be approximately 153 nm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a prior art hybrid amplifier.
FIG. 2 is a gain versus wavelength plot representing several components of the amplifier of FIG. 1 .
FIG. 3 is a schematic representation of a hybrid amplifier according to one embodiment of the invention.
FIG. 4 is a gain versus wavelength plot representing several components of the amplifier of FIG. 3 .
FIG. 5 is a schematic representation of a hybrid amplifier according to another embodiment of the invention.
FIG. 6 is a gain versus wavelength plot representing several components of the amplifier of FIG. 5 .
FIG. 7 is a flow chart showing a method according to one embodiment of the invention.
DESCRIPTION OF THE INVENTION
The presently-described invention is a multi-band hybrid SOA-Raman amplifier capable of amplifying all 8 CWDM channels typically used in today's commercial systems. As described herein, the unique design of this amplifier not only facilitates simultaneous amplification of the 8-channel band, but makes possible relatively long distance transmission via a multi-amplifier cascade.
The Hybrid Amplifier
The inventors recently measured gain and transmission system bit-error rate performance for a broadband (4 channels from 1510 nm to 1570 nm) hybrid amplifier based on a single SOA and a single Raman pump laser. That amplifier 100 , which has been previously demonstrated for DWDM systems, is shown schematically in FIG. 1 . A backward propagating semiconductor Raman pump laser 120 is coupled to the transmission fiber 110 with a wavelength division multiplexing (WDM) coupler 130 , followed by a conventional polarization independent SOA 140 and an optical isolator 150 .
The Raman pump wavelength is chosen to compliment the SOA such that the combined gain of the hybrid amplifier is both increased and flattened as compared to the SOA alone. A plot 200 of measured gains of the components of the hybrid amplifier of FIG. 1 is presented in FIG. 2 . Specifically, that figure shows the measured gain spectra 230 of the SOA alone (triangles), Raman amplifier 220 alone (diamonds), and the hybrid amplifier 250 (squares). In this case, the Raman pump laser operated at 1480-nm wavelength with 300-mW coupled into the transmission fiber, and the SOA gain peak was approximately 1510-nm wavelength. The transmission fiber, which is necessary to provide Raman gain, was 60 km of standard reduced water peak fiber (OFS AllWave® fiber). Similar performance is expected for other common transmission fiber types including standard single-mode fiber.
As shown by the curves of FIG. 2 , the SOA gain 230 decreases monotonically from short wavelength to long wavelength within the 4 channel CWDM band 210 . The Raman gain 220 has the opposite trend, increasing with increasing wavelength. Aside from the obvious gain enhancement and gain-tilt compensation, this amplifier arrangement has another more subtle advantage: this design alleviates the power penalty due to cross-gain modulation (saturation) in the SOA. The pre-emphasis of the long-wavelength channels by the Raman gain permits positioning of the 4 channel band 210 to the long-wavelength side of the SOA gain peak, where cross-gain modulation is reduced. Those three attributes make this amplifier far more promising as a candidate for multi-amplifier cascades. The increase in gain and gain flatness helps preserve optical signal-to-noise ratio over a multi-amplifier cascade, and the resistance to cross-gain modulation prevents signal degradation due to crosstalk. Naturally, with the proper choice of Raman pump wavelength and SOA gain peak, that same arrangement could be implemented to cover any contiguous 4 channel band within the 18-channel CWDM spectrum; however, higher pump power would be required at shorter wavelengths due to increased fiber loss.
The Hybrid Multi-Band Amplifier
Although the optical bandwidths of the SOA and Raman gain are naturally well suited to a 4-channel hybrid amplifier design, most commercial CWDM systems employ 8 CWDM channels from 1470 nm to 1610 nm. The inventors have developed novel two-band variations of the hybrid SOA-Raman amplifier capable of amplifying the entire commonly used 8 channel band. FIG. 3 is a schematic representation of a hybrid two-band amplifier 300 . Multiple pumps 320 , 322 , 324 , shown in the drawing as P 1 , P 2 and P 3 , are multiplexed together in a pump multiplexer 326 and coupled onto the transmission fiber 310 via an optical circulator 330 . The Raman amplified 8-channel spectrum is split into two 4-channel bands in the band demultiplexer 340 , and each band is separately amplified by SOAs (B 1 ) 342 and (B 2 ) 344 . The SOAs 342 , 344 are followed by optical isolators 350 , 352 , and the amplified bands are recombined in band multiplexer 355 .
Although the hybrid amplifier 300 of FIG. 3 is shown with three Raman pumps 320 , 322 , 324 , the number of pumps, pump wavelengths and pump powers may vary depending on the desired peak gain and gain shape. One exemplary configuration having three Raman pumps is represented in the plot 400 of FIG. 4 . The curve 420 (diamonds) shows the calculated on-off Raman gain for three pumps 320 , 322 , 324 with wavelengths 1365 nm, 1430 nm, and 1500 nm, and having pump powers of 200 mW, 250 mW, and 150 mW, respectively. The moderate net resulting Raman gain 420 , monotonically increasing across each of the two 4 channel bands, serves the same purpose as the Raman gain in the previously described single-band amplifier: it improves gain, improves optical signal-to-noise ratio (OSNR) and decreases gain tilt across each 4-channel band, while allowing operation in the low-crosstalk region of the SOA spectra. The 1500-nm pump, although falling within the overall 8-channel band, is situated at the null between the 1490-nm and 1510-nm channels and thus should not result in excessive Rayleigh backscattered pump light impinging on the channel receivers.
Typical SOA gains for SOAs (B 1 ) 430 (triangles) and (B 2 ) 432 (circles), respectively, are then added to the Raman gain resulting in the overall calculated net gain 450 of the hybrid two-band amplifier (squares). The net gain is relatively flat over the 8-channel band, with a peak gain of 21.2 dB at 1530 nm and a minimum gain of 17.7 dB at 1610 nm. The fact that Raman gain for a single pump wavelength naturally increases with increasing signal wavelength, results in a simpler and less costly Raman implementation for this 2-band hybrid amplifier as compared to an all-Raman design.
FIG. 5 shows a variation 500 of the two-band hybrid SOA-Raman amplifier which uses only one SOA 542 rather than two. The SOA 542 is followed by an optical isolator 550 and is between demultiplexer 540 and multiplexer 555 , as in the example of FIG. 3 . Signals 544 within one of the bands do not pass through an SOA. That simpler design comes at the expense of increased Raman pump powers. Three backward propagating pump lasers, P 1 ( 520 ) at 1365 nm, P 2 ( 522 ) at 1455 nm and P 3 ( 524 ) at 1500 nm, have output powers of 300 mW, 320 mW, and 220 mW, respectively.
Although only one SOA 542 is used, the proposed amplifier 500 still employs a dmux-mux pair 540 , 555 to split (combine) the 8-channel band before (after) SOA B 1 . That conservative design may not be necessary if SOA B 1 exhibits sufficiently low excess loss and polarization dependant loss (PDL) over the long wavelength half of the spectrum (in which case, the dmux and mux 540 , 555 can be omitted).
The calculated gain for this amplifier configuration is shown in FIG. 6 . Diamonds again represent the calculated Raman gain 620 . In this case, rather than a Raman gain spectrum that increases over each of the two 4-channel sub-bands, the Raman gain increases over the short wavelength 4 channel band (1470 μm, 1490 nm, 1510 nm, and 1530 nm), but remains relatively flat over the long wavelength 4-channel band (1550 nm, 1570 nm, 1590 nm, and 1610 nm). Thus, the Raman process provides all of the amplification for the long-wavelength sub-band, while the net short wavelength gain 650 (squares) is due to both Raman gain and the gain 630 from SOA B 1 (triangles).
For these particular Raman pump powers and SOA gain shape, this design exhibits slightly higher gain variation than the previous two-SOA design. The calculated net gain varies between a minimum of 17.4 dB and a maximum of 21.9 dB.
A Method According to the Invention
The invention described herein further contemplates a method 700 , shown in FIG. 7 , for amplifying a CWDM optical signal having at least first and second frequency bands. The wavelength spread occupied by the CWDM optical signal may be approximately 153 nm, the spread of many commercially-available CWDM systems. The CWDM optical signal may comprise an 8-channel spectrum split into two 4-channel bands.
The CWDM optical signal is amplified (step 710 ) using at least one Raman pump coupled to the optical fiber cable. The at least one Raman pump may be a plurality of pump lasers, each having a different wavelength. The bands of the CWDM optical signal may comprise channels having null frequency ranges between them, in which case a wavelength of at least one of the plurality of pump lasers may be within that null frequency, to prevent excessive Rayleigh backscattered pump light impinging on the channel receivers.
The amplified CWDM optical signal is then split (step 720 ) into frequency bands. At least one of the split frequency bands is further amplified (step 730 ) using a semiconductor optical amplifier (SOA). In a preferred embodiment, the net gain of the Raman amplifying step and the SOA amplifying step is flat over the CWDM frequency range to within 5 dB. Each band of the CWDM signal may be separately amplified by an SOA. The bands are then recombined (step 740 ).
SUMMARY
The inventors have proposed several new multi-band hybrid SOA-Raman amplifier designs for CWDM transmission systems. Both implementations are capable of simultaneously amplifying 8 CWDM channels from 1470-1610 nm. Calculations made by the inventors suggest that those cost effective designs will outperform both all-SOA and all-Raman amplifiers in terms of peak gain, gain shape and crosstalk tolerance, and are therefore well suited to applications that require cascaded amplifiers. Furthermore, the maximum individual pump powers required for each of the two designs (250 mW and 300 mW, respectively) are readily available from commercial semiconductor pump lasers.
The foregoing Detailed Description is to be understood as being in every respect illustrative and exemplary, but not restrictive, and the scope of the invention disclosed herein is not to be determined from the Detailed Description, but rather from the claims as interpreted according to the full breadth permitted by the patent laws. For example, while the method of the invention is described herein with respect to optical transmission using CWDM, the method and apparatus of the invention may be used with other optical multiplexing schemes wherein a relatively wide wavelength band width is occupied by the signal. It is to be understood that the embodiments shown and described herein are only illustrative of the principles of the present invention and that various modifications may be implemented by those skilled in the art without departing from the scope and spirit of the invention. | A multi-band hybrid amplifier is disclosed for use in optical fiber systems. The amplifier uses Raman laser pumps and semiconductor optical amplifiers in series to produce a relatively level gain across the frequency range of interest. Multiple Raman pumps are multiplexed before coupling into the fiber. The Raman amplified optical signal may be demultiplexed and separately amplified by the SOAs before re-multiplexing. Gain profiles of the Raman pumps and the SOAs are selected to compensate for gain tilt and to alleviate the power penalty due to cross-gain modulation in the SOAs. The disclosed hybrid amplifier is especially useful in coarse wavelength division multiplexing (CWDM) systems. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a waste oil delivery system and more particularly to a simplified system for delivering waste oil to a burner or heater which may be located a long distance from and elevated well above an oil reservoir.
Numerous varieties of heaters or burners are known, and these include heaters and burners which utilize the combustion of oil to produce heat. Typically, the oil is delivered from an oil source or reservoir, such as a tank, to an orifice in a nozzle located adjacent to or in a combustion chamber. The nozzle and the orifice may mechanically atomize the oil (a so-called "hydraulic combustion system") and/or admix air to aerate it (a so-called "air atomizing combustion system") to produce an aerosol thereof. In either event, the oil, now mechanically broken up into micro-globules, is directed into the combustion chamber, where it is burned to produce heat.
Oil burners and heaters are often capable of combusting fuel oils ranging from No. 1 fuel oil--a volatile, distillate oil--to No. 6 fuel oil--a high-viscosity fuel--to waste oils. Prior art fuel oil delivery systems have utilized a single pump, located physically near the burner or heater. The low side of the pump is connected to a line to which the pump applies a negative pressure (about 10-12 inches of mercury) to pull the fuel oil into the pump. Thereafter, the pump transmits the oil to its high side for subsequent delivery through a delivery line to the nozzle or its orifice. A practical limit on the maximum distance between the fuel reservoir and the low side of the pump is imposed by the physics of lifting liquids by negative pressure. This practical limit is a head lift of about fourteen feet. Thus, the use of single pump prior art fuel oil delivery systems is limited to residences and commerical buildings of moderate height (where the tank is at or near ground level) or to the ground level of a building (where the tank is buried). Higher buildings or deeper tank depths require multiple, or booster, pump systems, or multiple tanks and delivery systems periodically spaced throughout the levels of the building.
Thus, one hallmark of prior art oil delivery systems is a reliance on "pulling" fuel oil to the burner or heater.
The type pump most often found in prior art oil delivery systems typically regulates its output pressure to a selected value by means of an internal or adjunct pressure regulator. A relief valve or similar relief device, may also be provided to bypass excess oil, that is, oil in excess of that required to maintain the selected output pressure, back to the reservoir. The output pressure at the high side of the pump is usually with the range of 75-300 pounds per square inch where the oil is non-waste oil which is burned in a hydraulic combustion system. Where the fuel oil is waste oil or other oil burned in an air atomizing combustion system, the pressure of the oil at the high side of the pump is maintained by the pump at about 10 pounds per square inch.
The high side of the pump in a prior art fuel oil delivery system moves pressure-regulated fuel oil through the line connected thereto to the nozzle. The amount of pressure regulation or bypassing which occurs at the pump varies at the viscosity of the oil. Viscosity, in turn, is dependent on the inherent characteristics of the fuel oil (e.g., its chemical make-up) and the temperature thereof. Because of these variables, the flow rate of the fuel oils to the nozzle is difficult to control by pressure regulation.
The range of pressures which may be experienced at the high side of the pump and the difficulty in controlling the flow rate of the fuel oil to the nozzle has led to the use of pressure regulators in the high side line between the pump and the nozzle. Such regulators maintain the pressure of the fuel oil delivered to the nozzle within a range of about 3 to 5 pounds per square inch. Typically, the regulator is "automatic" and regulates the upstream pressure of the fuel oil as the pressure of the oil delivered to the nozzle varies.
In order to "match" the amount of oil delivered to the nozzle and the requirements of the particular combustion zone with which the nozzle is used, the size of the orifice in the nozzle may be appropriately selected.
Thus, another hallmark of prior art fuel oil delivery systems is the reliance on pressure regulation and orifice size to control and regulate the flow rate of fuel oil to the nozzle.
The above-described limitation on the distance from which, and the height to which, fuel oil may be delivered, the difficulty in controlling flow rate of fuel oil to a nozzle, and the need to rely on pressure regulation and orifice site to achieve desired oil flow are factors adversely affecting the applicability and economy of present fuel oil burner and heater systems. An object of the present invention is to eliminate or ameliorate these factors by the use of a simple, economical fuel oil delivery system.
SUMMARY OF THE INVENTION
With the above and other objects in view, the present invention contemplates a simple heating oil delivery system for delivering waste oil from a source of oil to a burner or heater. The burner or heater may be located a long distance from and/or may be elevated well above the reservoir, which may be a storage tank, which is located above ground or is buried. The oil delivery system is similar only in a general way to prior art systems: it delivers fuel oil from the reservoir to a combustion zone of a heater or burner, and the fuel oil is introduced into the combustion zone following atomization thereof upon exiting an orifice of a nozzle. However, in prior systems: (1) the oil is received in the orifice at a predetermined pressure due to the action of pressure regulation upstream of the nozzle and (2) the predetermined pressure and the size of the orifice control the flow rate of the oil out of the orifice and into the combustion zone. Neither of the two foregoing characteristics apply to the present invention.
The delivery system of the present invention is particularly adapted for use with an air-atomizing combustion system which burns waste oil, although other oils may be used. A positive displacement metering pump, which includes no pressure-regulating or by-pass facilities, is usually located physically close to the oil reservoir and remote from the nozzle. The pump removes the oil from the source and thereafter pushes the oil to deliver it to the nozzle. The oil is delivered to the nozzle at a constant flow rate regardless of its pressure in the orifice or the size of the orifice. No pressure-regulating facilities between the pump and the nozzle are utilized.
The distance between the pump and the nozzle may exceed fourteen feet and may be about one-hundred feet or more. Heating pads adjacent the delivery line between the pump and the nozzle may heat the oil. Preferably, the pads are located proximate to the nozzle.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic view of a fuel oil delivery system according to the prior art; and
FIG. 2 is a schematic view of a fuel oil delivery system according to the present invention.
DETAILED DESCRIPTION
Referring to FIG. 1, there is schematically depicted a fuel oil delivery system 10 according to the prior art. The delivery system 10 delivers fuel oil 12 from source or reservoir 14 thereof, such as a tank, to a combustion zone 16 of a burner, heater or similar heat-producing system 17. The fuel oil 12 is introduced into the combustion zone 16 in atomized form 18.
Atomization 18 of the oil 12 is effected by a nozzle 20 having an orifice 22 therein through which the oil 12 passes. If the system 10 is a so-called "hydraulic" system, atomization 18 of the oil 12 is achieved by its passage through and out of the orifice 22. If the system 10 is a so-called air-atomizing system, air is admixed with the oil 12 in the orifice 22, as depicted at 24, to aerate it. In either event, the atomized oil 18, now broken up into micro-globules, is burned within the combustion zone 16 to produce heat.
Typically, the oil 12 is removed from the reservoir 14 by the action of a pump 30. In standard arrangements, the pump 30, the nozzle 20 and other related elements of the burner 17 are physically proximate and are included in a common "package" comprising the burner system 17. More specifically, the distance 32 between the pump 30 and the nozzle 20 is relatively short, while the distance 34 between the pump 30 and the reservoir 14 is relatively substantially longer. The oil 12 is drawn from the reservoir 14 by the pump 30 applying a negative pressure via its low side 30L to a line 36, an inlet 38 of which is immersed in the oil 12. As is well known, this type of pumping, termed herein as "pulling" is limited by physical considerations to lifting the oil 12 to a height H no greater than about fourteen feet. The oil 12 pulled into the pump 30 is then forced from the high side 30H thereof, through a line 38 to the proximate nozzle 20.
The pump 30 is usually pressure-self-regulated. That is, a pressure regulator 40, which may be internal to the pump 30 or which may be an external adjunct to the pump 30, regulates, as shown by the arrows 42, the pressure of the oil 12 at the high side 30H of the pump 30 and in the line 38 to a selected value. Pump 30, as used in prior art systems 10, may also utilize pressure-relief facilities 44, which by-pass the oil internally or feed back excess oil 12 to the reservoir 14 through a line 46. Often, due to factors related to the characteristics of the pump 30 (e.g., pulsing), the oil (e.g., viscosity) or other elements of the system 10 additional pressure regulation is utilized. To that end, the line 38 may include a pressure regulator 48, which controls the pressure of the oil 12 delivered to the nozzle 20, in accordance with regulation input, diagrammatically shown at 50, sent from a sensor 52, associated with the nozzle 20 and its orifice 22, to the regulator 48.
Where the system 10 is used with hydraulic combustion and the oil 12 is non-waste oil, the pressure of the oil 12 at the high side 30H of the pump 30 is typically within a range of 75-300 lb/in 2 . If the system 10 is used with air-atomizing combustion and delivers waste oil, this pressure is about 10 lb/in 2 . The regulator maintains the pressure of the oil 12 delivered to the nozzle 20 to between about 3-8 lb/in 2 .
If required, as may be the case where the oil 12 is waste oil, the oil in the line 38 is heated, as shown by the arrow 54, in any convenient manner.
Prior art oil delivery systems 10 are, therefore, characterized by:
(1) Delivering fuel oil 12 by pulling it from the reservoir 14--this limits the height H to which the oil 12 can be lifted; and
(2) Reliance on pressure regulation, in the pump 30 and/or via pressure regulation facilities 48, 50, 52, and the size of the orifice 22 to control the flow rate of the oil 12 into the combustion zone 16--This renders the system 10 expensive and complicated, and, nevertheless, often results in poor or improper flow rates of the oil 12.
A system 100 according to the present invention is shown in FIG. 2, wherein like reference numerals denote similar elements to those in FIG. 1. The system 100 achieves improved delivery of oil 12 to the combustion zone 16 by virtue of the simplification and rearrangement of the system 10 of FIG. 1.
A pump 102 is used to move oil 12 from the reservoir 14 to the nozzle 20 for burning in the combustion zone 16. The pump 102 is preferably a positive displacement, metering pump and may be a gear pump, such as a ring gear pump of the type available from Sun Tec Industries under the designation fuel pump. The pump 102 may be basically similar to the pump 30, but it includes no pressure-regulation facilities 40, 42. The pump 102 draws the oil 12 from the reservoir 14 via a line 104 having an inlet 106 and delivers the oil 12 to the nozzle 20 via a line 108. The pump 102 is located proximate to the reservoir 14 and is not usually proximate to the nozzle 20. This locational change from the prior art system 10 of FIG. 1 permits oil 12 to be delivered to great heights H and/or to nozzles 20 located substantial distances away therefrom. Thus, in contrast to FIG. 1, the pump-to-reservoir distance 34 has been shortened to 34' and nearly eliminated, while the pump-to-nozzle distance 32 has been lengthened to 32' with oil lifts H' far greater than H being achieveable.
The metering pump 102 of the system 100 "pushes" the oil 12 to the nozzle 20. Because of this and the foregoing considerations, the flow rate of the oil 12 to the nozzle 20 is a function of the design and operating parameters of the pump 102 and not of pressure. Accordingly, the pressure-regulating facilities 48, 50, 52 as well as those 40, 42 associated with the pump 30 are eliminated. The size of the orifice 22 also does not, within practical limits, i.e., excluding orifices of zero (or extremely small) or infinite (or extremely large) diameter, determine the flow rate of the oil 12 into the combustion zone 16.
The foregoing improved system 100 is particularly adapted to deliver waste oil 12 to the nozzle 20. Where required for reasons of viscosity, low volatility or otherwise, the waste oil may be heated to a selected temperature by heating pads 110, located proximate to the nozzle 20, as shown by arrows 112.
A pressure relief valve 113 is installed on the push side of the pump 102 to provide pressure relief in the event of blockage in the supply line 108 or nozzle 20. | The distance between the combustion nozzle and the pump of a waste oil heater can be significantly increased by using a positive displacement pump which is proximate to the reservoir and remote from the nozzle, contary to the usual positioning of oil delivery pumps. The pump, which is not pressure regulated, thus pushes oil to the nozzle at a constant flow rate regardless of oil pressure at the nozzle. | 5 |
TECHNICAL FIELD
The invention relates generally to deriving tilt-corrected seismic data in a seismic sensor module having a plurality of sensing elements arranged in multiple axes.
BACKGROUND
Seismic surveying is used for identifying subterranean elements, such as hydrocarbon reservoirs, fresh water aquifers, gas injection reservoirs, and so forth. In performing seismic surveying, seismic sources are placed at various locations above an earth surface or sea floor, with the seismic sources activated to generate seismic waves directed into the subterranean structure. Examples of seismic sources include explosives, air guns, or other sources that generate seismic waves. In a marine seismic surveying operation, the seismic sources can be towed through water.
The seismic waves generated by a seismic source travel into the subterranean structure, with a portion of the seismic waves reflected back to the surface for receipt by seismic sensors (e.g., geophones, hydrophones, etc.). These seismic sensors produce signals that represent detected seismic waves. Signals from seismic sensors are processed to yield information about the content and characteristic of the subterranean structure.
For land-based seismic data acquisition, seismic sensors are implanted into the earth. Typically, seismic signals traveling in the vertical direction are of interest in characterizing elements of a subterranean structure. Since a land-based seismic data acquisition arrangement typically includes a relatively large number of seismic sensors, it is usually impractical to attempt to implant seismic sensors in a perfectly vertical orientation.
If a seismic sensor, such as a geophone, is tilted from the vertical orientation, then a vertical seismic signal (also referred to as a “compression wave” or “P wave”) would be recorded with attenuated amplitude. Moreover, seismic signals in horizontal orientations (also referred to as “shear waves” or “S waves”) will leak into the compression wave, where the leakage of the seismic signals into the compression wave is considered noise. Since the tilts of the seismic sensors in the land-based seismic data acquisition arrangement are unknown and can differ randomly, the noise will be incoherent from seismic sensor to seismic sensor, which makes it difficult to correct for the noise by performing filtering.
SUMMARY
In general, according to an embodiment, a seismic sensor module includes sensing elements arranged in a plurality of axes to detect seismic signals in a plurality of respective directions. The seismic sensor module also includes a processor to receive data from the sensing elements and to determine inclinations of the axes with respect to a particular orientation. The processor is to further use the determined inclinations to combine the data received from the sensing elements to derive tilt-corrected seismic data for the particular orientation.
Other or alternative features will become apparent from the following description, from the drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an exemplary survey arrangement that includes seismic sensor modules according to some embodiments.
FIGS. 2-3 illustrate an exemplary deployment of seismic sensor modules.
FIG. 4 is a schematic diagram of a seismic sensor module according to an embodiment.
FIG. 5 is a flow diagram of a process of deriving tilt-corrected seismic data in the seismic sensor module of FIG. 4 , according to an embodiment.
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 are possible.
FIG. 1 illustrates an example survey arrangement (spread) that includes an array of seismic sensor modules 102 . In accordance with some embodiments, the seismic sensor modules are multi-axis seismic sensor modules that each includes a processor to perform tilt correction to obtain seismic data along a vertical orientation (vertical direction) and to remove or reduce noise due to leakage of seismic signals propagating along horizontal orientations into the vertical seismic signal. More generally, the processor is able to obtain seismic data along a target orientation (which can be a vertical orientation, horizontal orientation, or any other orientation), and the processor is able to remove or reduce noise due to leakage of seismic signals propagating along other orientations into the seismic signal propagating in the target orientation.
The seismic sensor modules 102 are connected by communications links 104 (which can be in the form of electrical cables, for example) to respective routers 106 and 108 (also referred to as “concentrators”). A “concentrator” refers to a communications module that routes data between nodes of a survey data acquisition system.
Alternatively, instead of performing wired communications over electrical cables, the seismic sensor modules 102 can perform wireless communications with respective concentrators.
The concentrators 108 are connected by communications links 110 . Seismic data acquired by the seismic sensor modules 102 are communicated through the concentrators 106 , 108 to a central recording station 112 (e.g., a recording truck). The recording station 112 includes a storage subsystem to store the received seismic data from the seismic sensor modules 102 . The recording station 112 is also responsible for management of the seismic sensor modules and concentrators, as well as the overall network.
One or more seismic sources 114 are provided, where the seismic sources 114 can be activated to propagate seismic signals into a subterranean structure underneath the earth on which the arrangement of seismic sensor modules 102 are deployed. Seismic waves are reflected from the subterranean structure, with the reflected seismic waves received by the survey sensor modules in the survey spread.
FIG. 2 illustrates three seismic sensor modules 102 A, 102 B, 102 C that have been implanted into the earth 200 . Each seismic sensor module 102 A, 102 B, or 102 C includes a respective implantation member (e.g., anchor) 202 A, 202 B, or 202 C that has a tip to allow for ease of implantation. The seismic sensor module 102 B has been implanted into the earth 200 to have a substantially vertical orientation (vertical direction) such that the seismic sensor module 102 B is not tilted with respect to the vertical orientation (Z axis of the sensor module 102 B is parallel to the vertical orientation). Also shown are X and Y axes, which are the horizontal axes that are orthogonal to each other and orthogonal to the Z axis.
The seismic sensor module 102 C has been implanted to have a slight tilt such that the Z axis is at an angle β with respect to the vertical orientation. The seismic sensor module 102 A has a much larger tilt with respect to the vertical orientation; in fact, the seismic sensor module 102 A has been improperly implanted to lay on its side such that its Z axis is greater than 900 offset with respect to the vertical orientation.
As further depicted in FIG. 2 , each of the seismic sensor modules 102 A, 102 B, and 102 C includes a respective processor 210 A, 210 B, and 210 C. Each processor 210 A, 210 B, or 210 C is able to perform tilt correction according to some embodiments to correct for tilt of the respective seismic sensor module from the vertical orientation. After tilt correction, the Z, X and Y axes are properly oriented, as shown in FIG. 3 . More specifically, in FIG. 3 , the Z axis of each of the seismic sensor modules 210 A, 210 B, and 210 C is generally parallel to the vertical orientation. As a result, the seismic data along the Z axis is tilt-corrected with respect to the vertical orientation.
FIG. 4 illustrates a seismic sensor module 102 according to an embodiment. The seismic sensor module 102 has a housing 302 defining an inner chamber 303 in which various components can be provided. The components include seismic sensing elements 304 , 306 , and 308 along the Z, X, and Y axes, respectively. In one embodiment, the seismic sensing elements 304 , 306 , and 308 can be accelerometers.
The seismic sensing elements 304 , 306 , and 308 are electrically connected to a processor 210 in the seismic sensor module 102 . The “processor” can refer to a single processing component or to multiple processing components to perform predefined processing tasks. The processing component(s) can include application-specific integrated circuit (ASIC) component(s) or digital signal processor(s), as examples. The processing component(s) can be programmed by firmware or software to perform such tasks. The “processor” can also include filtering circuitry, analog-to-digital converting circuitry, and so forth (which can be part of or external to the processing circuitry).
The processor 210 is connected to a storage device 212 , in which tilt-corrected seismic data 214 computed by the processor 210 can be stored. The seismic sensor module 102 also includes a telemetry module 216 , which is able to send tilt-corrected seismic data over the communications link 104 (which can be a wired or wireless link). In accordance with some embodiments, instead of sending tilt-corrected seismic data in all three axes, just the tilt-corrected seismic data along a single axis (e.g., Z axis) is sent. As a result, communications link bandwidth is conserved, since the amount of seismic data that has to be sent is reduced. In one implementation, the telemetry module 216 sends the Z-axis tilt-corrected seismic data in one single telemetry channel, instead of multiple telemetry channels to communicate seismic data for all three axes. The phrase “telemetry channel” refers to a portion of the communications link bandwidth, which can be a time slice, a particular one of multiple frequencies, and so forth.
Referring further to FIG. 5 , the seismic sensing elements 304 , 306 , and 308 (e.g., accelerometers) record (at 502 ) seismic signals (particle motion signals) in the three respective Z, X, and Y axes. Also, each seismic sensing element 304 , 306 , and 308 records the component of the gravity field along the respective Z, X, or Y axis. The gravity field component recorded by each seismic sensing element is the DC component. In an alternative implementation, the seismic sensing elements 304 , 306 , and 308 can be implemented with a three-component ( 3 C) moving coil geophone.
The processor 210 determines (at 504 ) the inclinations of the seismic sensing elements 304 , 306 , and 308 . The inclination of each respective seismic sensing element is determined by extracting the DC component (expressed in terms of g or gravity) of the recorded signal from the seismic sensing element. The DC component can be extracted by taking an average of the recorded signal over time, or by filtering out the high-frequency components of the recorded signal (using a low-pass filter). The arccosine of the DC component provides the inclination of each axis (Z, X, or Y) with respect to the vertical orientation. Alternatively, if the seismic sensing elements 304 , 306 , and 308 are implemented with a 3 C moving coil geophone, then inclinometers can be used to measure the Inclinations of the elements.
If the seismic sensing elements 304 , 306 , and 308 are arranged to be exactly orthogonal to each other, then the inclinations of the seismic sensing elements 304 , 306 , and 308 with respect to the vertical orientation will be the same value. However, due to manufacturing tolerances, the seismic sensing elements 304 , 306 , and 308 may not be exactly orthogonal to each other, so that the inclinations can be slightly different.
Once the inclinations of the seismic sensing elements 304 , 306 , and 308 are known, the processor 210 rotates (at 506 ) the seismic data recorded by the seismic sensing elements 304 , 306 , and 308 to the vertical orientation and to the two orthogonal horizontal orientations, respectively. Rotating the seismic data involves extrapolating the recorded (tilted) seismic data to the respective vertical or horizontal orientation, as well as removing any noise caused by leakage into a seismic signal along a first orientation (e.g., vertical orientation) of seismic signals in other orientations (e.g., horizontal orientations).
Next, the vertical tilt-corrected seismic data only is sent (at 508 ) by the seismic sensor module 102 . By sending just the vertical tilt-corrected seismic data and not the horizontal seismic data, communications link bandwidth is conserved. In alternative embodiments, instead of sending just the vertical seismic data, horizontal tilt-corrected seismic data can be sent instead. In fact, the seismic sensor module 102 can be selectively programmed or instructed by the recording station 112 (such as in response to a command by a human operator) to send tilt-corrected seismic data along a particular orientation. Also, the operator can select that non-tilt-corrected seismic data along one or more orientations is sent, which may be useful for test, trouble-shooting, or quality control purposes. As yet another alternative, different signal orientations can be sent from different sensor modules, at different spatial spacing. For example, vertical direction can be selected for all sensor modules, and horizontal direction(s) can be selected for only a subset of these sensor modules.
In a different implementation, techniques according to some embodiments can be applied in a seismic data acquisition arrangement that uses just shear-wave seismic sources (e.g., shear-wave acoustic vibrators). As a result, a seismic sensor module will record in just the X and Y horizontal orientations. If the seismic sensor module further includes a compass or magnetometer, then the X and Y seismic signals can be rotated to account for inclinations with respect to any target azimuth (e.g., source-receiver direction or perpendicular to the source-receiver direction, to obtain radial or transverse energy from the shear wave generated by the shear-wave seismic source). After rotation, just the seismic data along one direction has to be sent.
In the same survey, compression-wave seismic sources can also be activated, with the seismic sensor module recording the seismic signal along the vertical orientation. In this case, only the vertical seismic data would be transmitted by the seismic sensor module for recording in the recording station 112 ( FIG. 1 ).
In addition to the tasks depicted in FIG. 5 , alternative implementations can also perform seismic sensor module calibration between tasks 502 and 504 . Also, filtering can be applied between tasks 502 and 504 , and/or between 506 and 508 , to filter out noise such as ground roll noise, which is the portion of a seismic source signal produced by a seismic source that travels along the ground rather than travels into the subterranean structure.
While the invention has been disclosed with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover such modifications and variations as fall within the true spirit and scope of the invention. | A seismic sensor module includes sensing elements arranged in a plurality of axes to detect seismic signals in a plurality of respective directions, and a processor to receive data from the sensing elements and to determine inclinations of the axes with respect to a particular orientation. The determined inclinations are used to combine the data received from the sensing elements to derive tilt-corrected seismic data for the particular orientation. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of and claims the benefit of U.S. patent application Ser. No. 09/486,582, filed Jul. 10, 2000, now pending, which application is incorporated herein by reference in its entirety, and which application is the National Phase of International Application No. PCT/SG97/00037, filed Aug. 29, 1997, incorporated herein by reference in its entirety.
BACKGROUND
1. Technical Field
This invention relates to digital signal decoding for the purposes primarily of audio reproduction. In particular, the invention relates to enhanced synthesis sub-band filtering during decoding of digital audio signals.
2. Description of the Related Art
In order to store or transmit data representing audio signals it is often desirable to first encode or compress the data so as to enable it to be stored or transmitted more efficiently. Decoding the data requires that the stored or transmitted data be reconstructed into audio signals by application of a decoding or decompression technique. The reconstruction process is typically quite computationally intensive, yet the process should be fast and reliable enough to enable the audio signals to be reconstructed in real time, on the fly, for example. In order for the decoding process to be carried out in relatively low-cost consumer products, the hardware utilised by the decoder should also preferably be relatively simple and inexpensive, or at least to the greatest extent reasonably possible.
Efficient stereo and multichannel digital audio signal coding methods have been developed for storage or transmission applications such as Digital Audio Broadcasting (DAB), Integrated Service Digital Network (ISDN), High Definition Television (HDTV) and Set Top Box (STB) for video-on-demand. The formats used to encode and reciprocally decode digital audio and video information for storage and retrieval is subject to various standards, one of which has been established by the Moving Pictures Experts Group and is known as the MPEG standard.
A standard on low bit rate coding for mono or stereo audio signals was established by MPEG-1 Audio, published under ISO-IEC/JTC1 SC29 11172-3, entitled “Coding of Moving Pictures and Associated Audio for Digital Storage Media at up to About 1.5 Mbits”, and the disclosure of that document is incorporated herein by reference. MPEG-2 Audio (ISO/IEC 13818-3) provides the extension to 3/2 multichannel audio and an optional low frequency enhancement channel (LFE). The audio part of the standard, ISO/IEC 11172-3, defines three algorithms, Layer 1, 2 and 3 for coding PCM audio signals. MPEG-2 (Multichannel) also defines Layer 1, 2, and 3 algorithms.
The MPEG audio encoder processes a digital audio signal and produces a compressed bitstream for transmission or storage. The encoder algorithm is not standardised, and may use various means for encoding such as estimation of the auditory masking threshold, quantisation, and scaling. However, the encoder output must be such that a decoder conforming to the above-mentioned standards specification will produce audio suitable for the intended application.
The decoder, subject to the application-dependent parameters, accepts the compressed audio bitstream in the defined syntax, decodes the data elements and uses the information to produce digital audio output, also according to the defined standard. The decoder first unpacks the received bitstream to recover the encoded audio information frame by frame.
After the process of frame unpacking, the decoder performs an inverse quantisation (expansion process) and feeds a sub-band synthesis filter bank with a set of 32 scaled-up sub-band samples in order to reconstruct the output PCM audio signals. The sub-band filter banks used for Layer 1 and Layer 2 of MPEG 1 audio decoder and Layer 1 and Layer 2 of MPEG2 (Multichannel extension) audio decoder, are the same.
The sub-band synthesis filter is one of the most computationally intensive blocks of the MPEG audio decoder. Sub-band filtering is performed for each sub-band in a frame and for every channel. Any reduction in its computational requirements thus enables less complexity and reduced cost of decoding.
BRIEF SUMMARY
In accordance with the present invention there is provided a method of decoding digital audio data, comprising the steps of obtaining an input sequence of data elements representing encoded audio samples, calculating an array of sum data and an array of difference data using selected data elements from the input sequence, calculating a first sequence of output values using the array of sum data, calculating a second sequence of output values using the array of difference data and forming decoded audio signals from the first and second sequences of output data.
Preferably, the array of sum data is obtained by adding together respective first and second data elements from the input sequence, the first and second data elements being selected from mutually exclusive sub-sequences of the input sequence. Furthermore, the array of difference data is preferably obtained by subtracting respective first data elements from corresponding second data elements of the input sequence, the first and second data elements being selected from mutually exclusive sub-sequences of the input sequence.
In one form of the invention the step of calculating an array of sum data and an array of difference data comprises dividing the input data sequence into first and second equal sized sub-sequences, the first sub-sequence comprising the high order data elements of the input sequence and the second sub-sequence comprising the low order data elements of the input sequence, calculating the array of sum data by adding together each respective data element of the first sub-sequence with a respective corresponding data element of the second sub-sequence, and calculating the array of difference data by subtracting each respective data element of the first subsequence from a respective corresponding data element of the second sub-sequence.
The invention also provides method of decoding a sequence of m, m an even positive integer, input digital audio data samples S[k], where k=0, 1, . . . (m−1), to produce a set of n, an even positive integer, output audio data samples V[i]. where i=0, 1, . . . (n−1), comprising the steps of:
a) calculating an array of sum data S ADD [k] according to
S ADD [k]=S[k]+S[m− 1 −k ] for k= 0, 1, . . . ( m/ 2−1)
b) calculating an array of difference data S SUB [k] according to
S SUB [k]=S[k]−S[m− 1 −k ] for k= 0.1 . . . ( m/ 2−1)
c) calculating a first output audio data sample by a multiply-accumulate operation according to
V
[
2
i
]
=
V
[
2
i
]
+
N
[
2
i
·
k
]
*
S
ADD
[
k
]
for
k
=
0
,
1
,
…
(
m
/
2
-
1
)
where
N
[
2
i
,
k
]
=
cos
[
(
32
+
2
i
)
(
2
k
+
1
)
π
64
]
d) calculating a second output audio data sample by a multiply-accumulate operation according to
V
[
2
i
+
1
]
=
V
[
2
i
+
1
]
+
N
[
2
i
+
1
,
k
]
*
S
SUB
[
k
]
for
k
=
0
,
1
,
…
(
m
/
2
-
1
)
where
N
[
2
i
+
1
,
k
]
=
cos
[
(
32
+
(
2
i
+
1
)
)
(
2
k
+
1
)
π
64
]
e) and repeating steps c) and d) for i=0, 1, . . . (n/2−1) to obtain a full set of output data.
The invention further provides a synthesis subband filter for use in decoding digital audio data, comprising a means for receiving or retrieving an input sequence of data elements comprising encoded digital audio data, a pre-calculation means for calculating an array of sum data and an array of difference data using selected data elements from the input sequence, and a transform calculation means for calculating a first sequence of decoded output values using said array of sum data and a second sequence of decoded output values using said array of difference data
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The invention is described in greater detail hereinbelow, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is a block diagram of major functional portions of an MPEG audio encoder;
FIG. 2 is a block diagram of mayor functional portions of an MPEG audio decoder;
FIG. 3 is a flow diagram of an MPEG decoding procedure;
FIG. 4 is a flow diagram showing a generalised form of a procedure according to the present invention; and
FIG. 5 is a flow diagram illustrating a preferred implementation of the invention.
DETAILED DESCRIPTION
FIG. 1 is a block diagram illustrating the major components of an MPEG audio encoder circuit 2 constructed in accordance with the aforementioned standards document. In the figure, an input signal 4 , comprising a pulse code modulated (PCM) signal having a 48 kHz sampling frequency and a sample size of 16 bits per sample, is provided as input to the single channel encoder 2 . The input signal is first mapped from the time domain into the frequency domain by a sub-band filter bank 8 . The resulting coefficients are normalized with scale factors which may be transmitted as side information. The coefficients thus obtained are then quantized and entropy encoded by a quantizer and encoding circuit 10 . Masking thresholds of the quantization errors are calculated based on psychoacoustic values provided by a psychoacoustic model 14 to control the quantization step. The bit allocation is transmitted as side information. The coded signal is then multiplexed by a frame packing circuit 12 and an encoded bitstream 6 is produced at the output of the encoder 2 .
A block diagram illustrating the main components of an MPEG audio decoder circuit 20 is shown in FIG. 2 . In the figure, an encoded bitstream 22 is provided to the input of the decoder. A bitstream unpacking and decoding circuit 26 performs an error correction operation if such operation was applied in the encoder. The bitstream data are unpacked to recover the various pieces of encoded information, and a reconstruction circuit 28 reconstructs the quantized version of the set of mapped samples from the frames of input data.
An inverse mapping circuit 30 transforms the mapped samples back into a uniform pulse code modulated (PCM) output signal 24 that reproduces the corresponding input signal which was provided to the encoder.
The foregoing descriptions of the encoder and decoder are specific to the MPEG standard, and it is considered to be within the skill of those in the art to implement the various hardware functions described above. Accordingly, a more detailed hardware description of an MPEG coding system is not considered necessary for a full and complete understanding of the invention. It should be appreciated the invention described herein, although described in connection with the MPEG coding standard, is considered useful for other coding applications and standards.
Referring to FIG. 3 , there is shown a flow diagram 40 of steps involved in signal processing in layers I and II in an MPEG1 audio decoder. To begin with, the bit allocation of an input bitstream ( 42 , 44 ) is decoded ( 46 ). Thereafter, various scale factors are also decoded ( 48 ) and the samples are requantized ( 50 ). The encoded signal is decoded in a synthesis sub-band filter ( 52 ) and the decoded pulse code modulated signals are output ( 54 , 56 ) for further processing and/or real time reproduction. The present invention relates primarily to the synthesis sub-band filter portion of the decoding process, when implemented for MPEG decoding.
The synthesis sub-band filter bank is composed of two main functions, an Inverse Modified Discrete Cosine Transform (IMDCT) and an Inverse Pseudo-Quadrature Mirror Filter (IPQMF). The IMDCT, which can be viewed as an overlap transform, performs a 32×64 cosine modulation transformation, which means a frequency shift of a filter bank into one single filter.
Consider a system in which output sub-band audio signal samples V i (i=0 . . . 63) are decoded from sequences of 32 encoded input samples S k , k=0 . . . 31. The inverse MDCT of the sequence S k , is defined as follows:
V
i
=
∑
k
=
0
31
cos
[
(
16
+
i
)
(
2
k
+
1
)
π
64
]
*
S
k
for
i
=
0
,
1
,
…
63
(
1
)
Taking the cosine symmetric property wherein:
cos 0=cos(2π−0) (2)
the IMDCT definition equation (1) may be modified as given below to implement a 32-point IMDCT. The remaining 32 output audio signal samples are obtained after post-processing from this IMDCT of S.
V
i
=
∑
k
=
0
31
cos
[
(
16
+
i
)
(
2
k
+
1
)
π
64
]
*
[
S
k
+
(
-
1
)
i
*
S
31
-
k
]
for
i
=
0
,
1
,
…
31
(
1
)
This equation (3) may be computed according to the following algorithm:
repeat i = 32 times
repeat k = 16 times
if I is even, Sum = S[k] + S[31 − k]
if l is odd, Sum = S[k] − S[31 − k]
V[i] = V[i] + N[i, k] * Sum
end k
end i
where
i
is the index of output samples (i = O . . . 31)
k
is the index of input samples (k = O . . . 15)
N(i, k) =
cos
[
(
32
+
2
i
)
(
2
k
+
1
)
π
64
]
S[k]
represents the input sample data sequence
V[i]
represents the output of IMDCT
The IMDCT equation, making use of the symmetrical property, is given in Equation (3) above, and the computational effort required for MPEG audio decoding is in large part dependant upon the efficiency with which the input samples can be processed through the IMDCT to obtain respective sub-band filter PCM samples. Embodiments of the present invention are able to reduce the number of arithmetic operations performed in implementing the IMDCT portion of the decoder, to thereby increase the computational efficiency of the decoding process. In particular, the number of addition operations required for the implementation of this equation can be reduced substantially by pre-computing the sum and difference of the sample data which is the input to the IMDCT. In addition, the pre-computation can take place outside the main IMDCT computational loop. Hence the main loop contains only the MAC operations, which can be executed very efficiently by any general purpose DSP in a minimum number of cycles.
In the present invention the dequantised sample data (e.g., 32 samples) from the encoded bitstream is pre-processed as per the symmetrical property of the cosine coefficients. The sample data is then split into two banks, each containing 16 samples. The sum and difference of respective data elements in the two banks is computed and stored in two arrays. These arrays are used as the input data for the subsequent MAC operations.
Prior art implementations of equation (3) have required 32×16 Multiply-Accumulate operations and 32×16 Addition operations. By using the pre-computation operations described above, however, the number of Addition operations reduces to 2×16. This results in a saving of 30×16 Addition operations per Sub-band filter implementation, which in turn translates to a corresponding reduction in overall computational power.
In the IMDCT equation (3), S k represents a sequence of m input data samples, where k=0 . . . (m−1). In a typical implementation for MPEG decoding 32 input data samples may be processed, such that m=32. For pre-computing the sum and difference of respective data elements, the input data sample sequence is first arranged into two equally sized data banks, one constituting the high order data elements and the other the low order data elements:
Data bank(1) S k for k= 0 . . . ( m/ 2)−1
Data bank(2) S k for k =( m/ 2) . . . ( m− 1)
For example, in a preferred embodiment of the present invention where m=32, S k is split into two data banks comprising:
S k for k= 0 . . . 15 (1)
S k for k= 16 . . . 31 (2)
The sum and difference data are calculated using respective data elements from the two data banks and is stored in two arrays of data, S ADD and S SUB which are computed as follows:
S ADD [k]=S[k]+S[m− 1 −k ] for k= 0, 1 ( m/ 2)−1 (4)
S SUB [k]=S[k]−S[m− 1 −k ] for k= 0, 1 ( n/ 2)−1 (5)
In the aforementioned example of 32 input data samples, equations (4) and (5) reduce to:
S ADD [k]=S[k]+S[ 31 −k ] for k= 0, 1, . . . 15
S SUB [k]=S[k]−S[ 31 −k ] for k= 0, 1, . . . 15
The IMDCT equation (3) may now be divided into two portions and rewritten as follows:
V
[
i
]
=
∑
k
=
0
15
cos
(
32
+
i
)
(
2
k
+
1
)
π
64
*
S
ADD
[
k
]
for
i
=
0
,
2
,
4
,
…
30
(
6
)
V
[
i
]
=
∑
k
=
0
15
cos
(
32
+
i
)
(
2
k
+
1
)
π
64
*
S
ADD
[
k
]
for
i
=
0
,
1
,
3
,
5
,
…
31
(
7
)
As shown in the above equations (6) and (7), the IMDCT may now be calculated in two passes, an ‘even pass’ where the sum of the sample data is used (equation (6)), and an ‘odd pass’ where the difference of the sample data is used (equation (7)). The computational algorithms of the above equations are shown below.
Calculation of sum and difference of sample data (Addition operations)
repeat k = 16 times
S ADD [k] = S k + S 3l−k
S SUB [k] = S k − S 3l−k
end k
Calculation of ‘even’ data of IMDCT (Multiply-Accumulate operations)
repeat i = 16 times
repeat k = 16 times
V[i] = V[i] + N[i,k]*S ADD [k]
end k
end i
Calculation of ‘odd’ data of IMDCT (Multiply-Accumulate operations)
repeat i = 16 times
repeat k = 16 times
V[i] = V[i] + N[I, k]*S SUB [k]
end k
end
i
where
i
is the index of output samples (i = 0 . . . 31)
k
is the index of input samples (k = 0 . . . 15)
N(i, k) =
cos
[
(
32
+
2
i
)
(
2
k
+
1
)
π
64
]
S[k]
represents the input sample data sequence
S ADD
represents the sum of data array
S SUB
represents the difference of data array
V[i]
represents the output of the IMDCT
FIGS. 4 and 5 illustrate the above procedure according to a preferred embodiment of the invention in the form of flow diagrams. The representation shown in FIG. 4 , illustrates the general steps involved, and the procedure illustrated in the flow diagram 80 of FIG. 4 corresponds to the synthesis sub-band filter step 52 of the overall decoding procedure 40 of FIG. 3 . To begin with the input samples S k are received ( 82 , 84 ) after having been isolated from the frames of encoded data received or retrieved. The input data samples are then utilised for pre-calculation of sum and difference data, as described above. This involves dividing the input data sample set into two equal sized sub-sets, which in the preferred embodiment consists of a first sub-set comprising the lower order data and a second sub-set comprising the higher order data. For example, in the case of 32 input samples S 0 to S 31 as described the first sub-set of input sample data may comprise the lower order input data S 0 to S 15 and the second sub-set comprises the upper order data samples S 16 to S 31 . Respective ones of each sub-set of input sample data are then used to obtain a sets of sum and difference data, S ADD and S SUB . As can be readily ascertained from the above description, in the preferred embodiment the calculation of the sum and difference data is performed using the lowest order samples from the first set with the corresponding highest samples from the second set. For example, in the case of 32 input samples, the sum and difference data elements may be calculated as follows:
S
ADD
[
0
]
=
S
[
0
]
+
S
[
31
]
S
SUB
[
0
]
=
S
[
0
]
-
S
[
31
)
S
ADD
[
1
]
=
S
[
1
]
+
S
[
30
]
S
SUB
[
1
]
=
S
[
1
]
-
S
[
30
]
S
ADD
[
2
]
=
S
[
2
]
+
S
[
29
]
S
SUB
[
2
]
=
S
[
2
]
-
S
[
29
]
…
…
…
…
S
ADD
[
15
]
=
S
[
15
]
+
S
[
16
]
S
SUB
[
15
]
=
S
[
15
]
-
S
[
16
]
Once the arrays of sum and difference data have been calculated, the multiply-accumulate operations required to calculate the IMDCT can be performed iteratively in two steps. The first step ( 88 ) is used to obtain half of the output samples (e.g., the “even” outputs) using the pre-calculated sum data comprising the S ADD data elements. The second step ( 90 ) is used to obtain the other half of the output samples (e.g., the “odd” outputs) using the pre-calculated difference data comprising the S SUB data elements. Each of these steps ( 88 , 90 ) is an iterative multiply-accumulate (MAC) operation involving each of the data elements from the respective S ADD or S SUB array. Furthermore, each of the MAC operations of steps 88 , 90 are performed repeatedly (step 92 ) to obtain a full complement of output samples. For example, where 32 output samples V 0 to V 31 are required, each of the iterative MAC steps 88 , 90 would be performed 16 times. Once the data for each output has been calculated, the data samples are output for PCM processing (step 94 ).
A more detailed preferred embodiment of the decoding procedure is illustrated in the flow diagram 100 shown in FIG. 5 . Beginning at step 102 , a sequence of m input samples S k (k=0 . . . m−1) are received for decoding to n sub-band filter outputs V i (i=0 . . . n−1) at step 104 . In the preferred embodiment for an MPEG implementation, both the number of input samples m and the number of output samples n are the same, 32. Steps 106 , 108 and 110 of procedure 100 form a loop for the pre-calculation process of determining and storing the sum and difference data arrays from the input data samples. The steps 112 , 114 , and 116 then form nested loops for the iterative multiple-accumulate calculation of the “even” ones of the output data elements (e.g., V i for i=0, 2, 4, . . . 30), using the pre-calculated sum data array S ADD . A calculation loop of steps 112 and 114 provides the iterative MAC operation, whilst the loop provided by step 116 , enables calculation of each (even) alternate output data element. The remaining (odd) alternate output data elements are calculated in nested loop steps 118 , 120 , 122 using the difference data array S SUB . The resulting output sub-band data is then provided at final step 124 .
The preferred form of the invention presented herein results in a reduction of 480 addition operations per 32 sub-band samples. For a stereo output MPEG1 Layer 2 audio decoder, this is a reduction of 480*36*2 arithmetic operations per frame. The overall reduction in arithmetic operations which is achieved is approximately 46.875% per IMDCT.
It will be readily apparent to those of ordinary skill in the relevant art that the present invention may be implemented in numerous different ways, without departing from the spirit and scope of the invention as described herein, and it is to be understood that such modifications are considered to be within the scope of the invention. In any event, it is immediately recognisable that one way the invention can be carried out, relating as it does to the processing of data, is using general purpose computing apparatus operating under the instruction of software or the like which is produced separately and specially adapted to perform the methods of the invention. Alternatively, specialised computing apparatus such as a dedicated integrated circuit, chipset or the like may be constructed with the functions of the invention embedded therein. Many other variations to the particular implementation will of course be possible. It will also be recognised that in places in the description and appended claims where it is said that a data set is divided into sub-sets, for example, this division may be simply a notional one, and no physical separation need occur, as is known in the data processing art.
The foregoing detailed description of the present invention has been presented by way of example only, and is not intended to be considered limiting to the invention which is defined in the claims appended hereto. | In order to reproduce audio signals which have been compressed or encoded for storage or transmission using, for example, MPEG audio encoding, a synthesis sub-band filter is employed which performs an inverse modified discrete cosine transform. The computational cost of the IMDCT implementation is reduced by pre-calculating arrays of sum and difference data. The arrays of sum and difference data are then used in two separate transform calculations, the results of which can be used in the generation of pulse code modulation audio data. | 7 |
RELATED APPLICATIONS
The present application is a division of U.S. application Ser. No. 11/296,300, filed Dec. 8, 2005, now abandoned, which claims priority from, Korea Application Number 10-2005-0008224, filed Jan. 28, 2005, the disclosures of which are hereby incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor package used in digital optical instruments and a method of manufacturing the same, and more particularly to a semiconductor package used in digital optical instruments and a method of manufacturing the same that is capable of minimizing the size of a semiconductor package having an image sensor, which is referred to as a complementary metal oxide semiconductor (CMOS) or a charge coupled device (CCD), through the application of a wafer level package technology, thereby reducing the manufacturing costs of the semiconductor package and accomplishing production on a large scale.
2. Description of the Related Art
Recently, portable home video cameras and digital cameras have been miniaturized. Furthermore, camera units have been incorporated into portable mobile phones. As a result, subminiature and high-resolution image sensor modules have been increasingly required. Such image sensor modules are composed of semiconductor packages, which must have an increased number of pixels because consumers desire excellent color reproduction and detailed expression and which must be light, thin, short, and small in addition to high density because the image sensor modules are applied to potable mobile phones.
FIG. 1A is a perspective view of a conventional semiconductor package 300 constituting an image sensor module illustrating the front part of the conventional semiconductor package 300 . The illustrated conventional semiconductor package 300 has a basic structure. Specifically, an image sensor or a light-receiving part 305 is formed on a silicon substrate, and a plurality of aluminum pads 310 are disposed around the image sensor or the light-receiving part 305 . FIG. 1B is a perspective view of the conventional semiconductor package 300 illustrating the rear part of conventional semiconductor package 300 .
Such a conventional semiconductor package 300 is generally applied to a camera module for mobile phones in one of three modes, such as a chip-on-board (COB) mode using a gold wire bonding technology, a chip-on-FPC (COF) mode using anisotropic conductive film (ACF) or non-conductive paste (NCP), and a chip-on-package (CSP) mode. Among the three modes, the CSP mode is widely used because the size of the semiconductor package manufactured in the CSP mode is very small, and the CSP mode is suitable for mass production.
CSP package structures and methods of manufacturing the same are well known. For example, the image sensor is mainly manufactured in a SHELL-OPC mode developed by Shellcase Ltd., which is one of the wafer level CSP modes.
FIGS. 2A , 2 B, and 2 C illustrate the structure of a conventional semiconductor package 350 manufactured in the above-mentioned SHELL-OPC mode. The conventional semiconductor package 350 is disclosed in International Patent Publication No. WO 99/40624. The semiconductor package 350 has a relatively thin and dense structure, which is protected from the external environment and is mechanically reinforced. A plurality of electric contacts 362 are plated along edge surfaces 364 .
The contacts 362 extend onto a flat surface 366 of the semiconductor package 350 via the edge surfaces 364 . Through this arrangement of the contacts 362 , the flat surface 366 of the semiconductor package 350 and the edge surfaces 364 can be attached to a circuit board. The conventional semiconductor package 350 has fusion bumps 367 formed at the ends of the respective contacts 362 . The fusion bumps 367 are arranged in a predetermined pattern.
FIG. 3 is a longitudinal sectional view illustrating the structure of another conventional semiconductor package 400 similar to the above-described semiconductor package. The conventional semiconductor package 400 is also disclosed in International Patent Publication No. WO 99/40624. The semiconductor package 400 includes a light-emitting unit and/or a light-receiving unit. The upper and lower surfaces of the semiconductor package 400 are formed of an electrically insulating and mechanical protecting material. At the upper surface and/or the lower surface of the semiconductor package 400 is disposed an integrated circuit die 422 , a transparent protective film 407 of which transmits light and electrically insulating edge surfaces 414 of which have pads.
The conventional semiconductor package 400 has a plurality of electric contacts 432 along the edge surfaces 414 . The conventional semiconductor package 400 also has a selective filter and/or a reflection-preventing coating film 445 formed at an outer adhesion surface 406 of the protective film 407 .
FIG. 4 is a longitudinal sectional view illustrating the structure of another conventional semiconductor package 450 , which is disclosed in International Patent Publication No. WO 01/43181. The conventional semiconductor package 450 includes a micro lens array 460 formed at a crystalline silicon substrate 462 . Below the silicon substrate 462 is disposed a package layer 466 , which is generally formed of glass. The package layer 466 is sealed by epoxy resin 464 . Electric contacts 478 are formed along the edge of the package layer 466 . Bumps 480 are normally formed by the electric contacts 478 . The electric contacts 478 are connected to the silicon substrate 462 by conductive pads 482 .
The conventional semiconductor package 450 is constructed such that a glass layer 494 and related spacer elements 486 are disposed on the silicon substrate 462 while being sealed by a bonding agent, such as epoxy resin 488 , and therefore, a space 496 is formed between the micro lens array 460 and the glass layer 494 . Preferably, the package layer 466 is transparent.
However, the structures of the above-described conventional semiconductor packages 400 and 450 are very complicated, and therefore, it is very difficult to manufacture the conventional semiconductor packages 400 and 450 .
FIG. 5 is a longitudinal sectional view illustrating the structure of another conventional semiconductor package 500 , which is manufactured in a mode different from the above-mentioned modes. The conventional semiconductor package 500 is disclosed in Japanese Patent Application No. 2002-274807. A transparent adhesion layer 508 is attached to a glass substrate 509 having a size corresponding to a plurality of semiconductor packages. Above the transparent adhesion layer 508 is disposed a silicon substrate 501 having a photoelectric conversion device region 502 formed at the lower surface thereof while a gap is formed between the silicon substrate 501 and the transparent adhesion layer 508 . In the illustrated structure, connection wires 507 are connected to a connection pad 503 of the silicon substrate 501 in the vicinity of the lower surface of the silicon substrate 501 .
After an insulation film 506 , rewiring layers 511 , columnar electrodes 512 , a packaging film 513 , and welding balls 514 are formed, the silicon substrate 501 is cut into pieces, and therefore, a plurality of semiconductor packages 500 each having the photoelectric conversion device region 502 are obtained. However, the structure of this conventional semiconductor packages 500 is very complicated, and therefore, it is very difficult to manufacture the conventional semiconductor package 500 .
FIG. 6 is a longitudinal sectional view illustrating the structure of yet another conventional semiconductor package 600 , which is different from the above-described conventional semiconductor packages. The conventional semiconductor package 600 is disclosed in Japanese Unexamined Patent Publication No. 2004-153260. The conventional semiconductor package 600 includes a pad electrode 611 formed on a semiconductor tip 610 , a supporting plate 613 attached to the surface of the semiconductor tip 610 , a via hole 617 formed from the inside surface of the semiconductor tip 610 to the outside surface of the pad electrode 611 , and a columnar terminal 620 connected to the pad electrode 611 in the via hole 617 .
At the columnar terminal 620 is formed a rewiring layer 621 , on which a solder mask 622 is coated. A bump electrode 623 is electrically connected to the rewiring layer 621 .
In the conventional semiconductor package 600 having the above-stated peculiar structure, wire breaking or deterioration of step coverage is effectively prevented, and therefore, the reliability of the conventional semiconductor package 600 having a ball grid array is increased.
However, the wavelength of light received by the above-mentioned semiconductor packages constituting the image sensor modules includes a visible spectrum, in which persons can see and recognize objects, in addition to an infrared spectrum and an ultraviolet spectrum.
For this reason, a camera module, in which the semiconductor package is mounted, has an infrared (IR) filter, by which infrared light transmissivity is decreased. Since the light in the infrared spectrum includes heat, the infrared light transmissivity is decreased and the reflexibility is increased by the IR filter, and therefore, the image sensor, which receives the light, is protected, and the transmissivity in the visible spectrum is increased.
According to the conventional art, a rectangular glass sheet is IR coated and is then cut into a plurality of IR filters, each of which is attached to the semiconductor package.
In this way, the semiconductor package is mounted to the camera module while the IR filter is separately attached to the semiconductor package according to the conventional art. That is, the conventional process is complicated, and therefore, improvement to the conventional process is required.
SUMMARY OF THE INVENTION
Therefore, the present invention has been made in view of the above problems, and it is an object of the present invention to provide a semiconductor package and a method of manufacturing the same that is capable of minimizing the size of the camera module and performing a packaging process at the wafer level step, thereby accomplishing mass production of the semiconductor package and reducing the manufacturing costs of the semiconductor package.
It is another object of the present invention to provide a semiconductor package and a method of manufacturing the same that is easily mounted through a reflow process, which is a conventional mounting process, at the step of mounting the semiconductor package on a printed circuit board (PCB), thereby improving assembly efficiency of the camera module.
It is yet another object of the present invention to provide a semiconductor package and a method of manufacturing the same that is capable of remarkably shortening a manufacturing process in chip-on-package (CSP) mode and not requiring attachment of an additional infrared (IR) filter to the camera module, thereby improving a manufacturing process of the semiconductor package and increasing productivity of the semiconductor package.
In accordance with one aspect of the present invention, the above and other objects can be accomplished by the provision of a semiconductor package used in digital instruments, the package comprising: a wafer made of a silicon material, the wafer having pad electrodes formed at one side surface thereof; an IR filter attached on the pad electrodes of the wafer by means of a bonding agent; terminals electrically connected to the pad electrodes, respectively, in via holes formed at the other side surface of the wafer, which is opposite to the pad electrodes; and bump electrodes, each of which is connected to one side of each of the terminals.
In accordance with another aspect of the present invention, there is provided 5 . A method of manufacturing a semiconductor package used in digital instruments, the method comprising the steps of: bonding an IR filter to a wafer, which has the pad electrodes formed at one side surface thereof and is made of a silicon material; removing the rear part of the wafer by cutting the rear part of the wafer such that the sum of the thickness of the wafer and the thickness of the IR filter is within the initial thickness of the wafer; forming via holes through the wafer from the rear surface of the wafer to the pad electrodes; forming terminals electrically connected to the pad electrodes in the via holes; forming bump electrodes on the terminals, respectively; and cutting the wafer into a plurality of semiconductor packages.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIGS. 1A and 1B illustrate the structure of a conventional semiconductor package, wherein
FIG. 1A is a perspective view of the conventional semiconductor package illustrating the front part of the conventional semiconductor package, and
FIG. 1B is a perspective view of the conventional semiconductor package illustrating the rear part of the conventional semiconductor package;
FIGS. 2A , 2 B, and 2 C illustrate the structure of another conventional semiconductor package, wherein
FIG. 2A is a perspective view of the conventional semiconductor package illustrating the front part of the conventional semiconductor package,
FIG. 2B is a perspective view of the conventional semiconductor package illustrating the rear part of the conventional semiconductor package, and
FIG. 2C is a perspective view of the conventional semiconductor package illustrating bump electrodes formed at the rear part of the conventional semiconductor package;
FIG. 3 is a longitudinal sectional view illustrating the structure of another conventional semiconductor package;
FIG. 4 is a longitudinal sectional view illustrating the structure of another conventional semiconductor package;
FIG. 5 is a longitudinal sectional view illustrating the structure of another conventional semiconductor package having bump electrodes;
FIG. 6 is a longitudinal sectional view illustrating the structure of yet another conventional semiconductor package having a via hole;
FIGS. 7A , 7 B, and 7 C illustrate the structure of a semiconductor package according to the present invention, wherein
FIG. 7A is a perspective view of the semiconductor package illustrating the front part of the semiconductor package,
FIG. 7B is a perspective view of the semiconductor package illustrating the rear part of the semiconductor package, and
FIG. 7C is a longitudinal sectional view of the semiconductor package illustrating an infrared (IR) filter and bump electrodes formed at the rear and front parts of the semiconductor package, respectively;
FIGS. 8A and 8B illustrate a semiconductor package manufacturing method according to the present invention, wherein
FIG. 8A is a view illustrating the structure of an IR filter glass layer, and
FIG. 8B is a sectional view illustrating a step of attaching the IR filter glass layer to a wafer;
FIG. 9 is a sectional view illustrating a step of cutting the rear part of the wafer in the semiconductor package manufacturing method according to the present invention;
FIGS. 10A and 10B illustrate via holes formed at the rear part of the wafer according to the present invention, wherein
FIG. 10A is a sectional view illustrating blind via holes, and
FIG. 10B is a sectional view illustrating through via holes;
FIGS. 11A and 11B illustrate terminals formed at the rear part of the wafer according to the present invention, wherein
FIG. 11A is a sectional view illustrating the terminals formed at the rear part of the wafer in the case of the blind via holes, and
FIG. 11B is a sectional view illustrating the terminals formed at the rear part of the wafer in the case of the through via holes;
FIGS. 12A and 12B illustrate conductive paste filled in the via holes according to the present invention, wherein
FIG. 12A is a sectional view illustrating the conductive paste filled in the blind via holes, and
FIG. 12B is a sectional view illustrating the conductive paste filled in the through via holes;
FIGS. 13A , 13 B, 13 C, and 13 D illustrate photosensitive resist applied on the terminals according to the present invention, wherein
FIG. 13A is a sectional view illustrating liquid-state photosensitive resist applied on the terminals in the case of the blind via holes,
FIG. 13B is a sectional view illustrating liquid-state photosensitive resist applied on the terminals in the case of the through via holes,
FIG. 13C is a sectional view illustrating photosensitive film resist applied on the terminals in the case of the blind via holes,
FIG. 13D is a sectional view illustrating photosensitive film resist applied on the terminals in the case of the through via holes;
FIGS. 14A and 14B illustrate via holes, interiors of which are filled according to the present invention, wherein
FIG. 14A is a sectional view illustrating the via holes, interiors of which are filled with resin, and
FIG. 14B is a sectional view illustrating the via holes, interiors of which are filled with conductive paste;
FIGS. 15A and 15B illustrate, in section, bump terminals formed at the terminals according to the present invention; and
FIGS. 16A and 16B illustrate semiconductor packages manufactured in the form of a wafer and cut into pieces according to the present invention, wherein
FIG. 16A is a view illustrating the structure of the wafer, and
FIG. 16B is a view illustrating, in detail, the structure of the semiconductor package.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.
A semiconductor package 1 according to the present invention is illustrated in FIGS. 7A , 7 B, and 7 C. FIG. 7A is a perspective view of the semiconductor package 1 illustrating the front part of the semiconductor package 1 , FIG. 7B is a perspective view of the semiconductor package 1 illustrating the rear part of the semiconductor package 1 , and FIG. 7C is a longitudinal sectional view of the semiconductor package 1 .
The semiconductor package 1 according to the present invention is manufactured in wafer level chip-on-package (CSP) mode. An infrared (IR) filter 10 is attached to the front surface of a wafer 20 , which has an image sensor 22 formed at the center thereof. A circuit 26 is formed at the rear surface of the wafer 20 , which is opposite to the image sensor 22 , using a lead-redistribution technology, and solder ball-shaped bump electrodes 30 are disposed at the circuit 26 using a ball grid array technology.
As shown in FIG. 7A , the wafer 20 of the semiconductor package 1 according to the present invention is made of a silicon material having a predetermined size. At one side surface of the wafer 20 are formed pad electrodes 28 , which are arranged along the edge of the wafer 20 . The image sensor 22 is formed at the center of the one side surface of the wafer 20 . In addition to the pad electrodes 28 , an insulating layer 28 a (see FIG. 8B ), which is composed of SiN 3 or SiO 2 , is also formed.
The IR filter 10 is attached on the pad electrodes 28 of the wafer 20 by means of a bonding agent 12 (see FIG. 8B ). The IR filter 10 is obtained by processing a glass sheet in the form corresponding to the wafer 20 and performing IR coating on one side surface of the glass sheet. The coating surface 10 a (see FIG. 8B ) may be formed at either the upper surface or the lower surface of the glass sheet. Preferably, the coating surface 10 a is formed at the glass sheet such that the coating surface 10 a is opposite to the wafer 20 .
Preferably, the bonding agent 12 , which bonds the IR filter 10 to the wafer 20 at the wafer level, is transparent and has excellent light transmissivity.
The semiconductor package 1 according to the present invention includes terminals 36 electrically connected to the pad electrodes 28 , respectively, in via holes 32 formed at the other side surface of the wafer 20 , which is opposite to the pad electrodes 28 .
The via holes 32 are formed through the wafer 20 from the rear surface of the wafer 20 to the pad electrodes 28 . The terminals 36 , which are made of metal, are formed in the via holes 32 , respectively.
As shown in FIGS. 7B and 7C , the terminals 36 constitute an electric circuit 26 at the rear surface of the wafer 20 .
Also, the semiconductor package 1 according to the present invention includes bump electrodes 30 , each of which is connected to one side of each of the terminals 36 .
Each of the bump electrodes 30 are made of solder balls, which are provided for each of the terminals 36 . As the bump electrodes 30 are formed at the rear surface of the wafer 20 , the semiconductor package is mounted to a printed circuit board (PCB) using a generalized reflow mounting technology, and therefore, a light, thin, short, and small semiconductor package module is constructed.
In the semiconductor package 1 according to the present invention, the sum of the thickness of the wafer 20 and the thickness of the IR filter 10 attached to the wafer 20 by means of the bonding agent 12 corresponds to the normal wafer level, and therefore, the size of the semiconductor package 1 is minimized.
Now, a method of manufacturing the semiconductor package with the above-stated construction according to the present invention will be described in detail.
The method of manufacturing the semiconductor package according to the present invention includes a step of bonding the IR filter 10 onto the wafer 20 , which has the pad electrodes 28 formed at one side surface thereof and is made of a silicon material.
At this step, as shown in FIG. 8A , a glass sheet is processed in the form corresponding to the wafer 20 , and IR coating is applied to one side surface of the glass sheet to prepare the IR filter 10 . In the conventional art, the glass sheet, preferably the rectangular glass sheet, is IR coated and is then cut into a plurality of IR filters 10 , each of which is attached to a camera module. According to the present invention, on the other hand, the wafer-shaped IR filter 10 is integrally attached to the wafer 20 , which is made of a silicon material, to manufacture the semiconductor package 1 .
Next, as shown in FIG. 8B , the glass layer of the IR filter 10 is bonded onto the wafer 20 by means of the bonding agent 12 . Preferably, the bonding agent 12 is transparent and has excellent light transmissivity.
The coating surface 10 a may be formed at either the upper surface or the lower surface of the IR filter 10 . Preferably, the coating surface 10 a is formed at the IR filter 10 such that the coating surface 10 a is opposite to one side surface of the wafer 20 where the pad electrodes 28 are formed. This is because the coating surface 10 a is protected during the process.
The method of manufacturing the semiconductor package according to the present invention further includes a step of removing the rear part of the wafer 20 by cutting the rear part of the wafer 20 such that the sum of the thickness of the wafer 20 and the thickness of the IR filter 10 is within the initial thickness of the wafer 20 .
At this step, as shown in FIG. 9 , the rear part of the wafer 20 , to which the glass layer of the IR filter 10 is not attached, is removed to decrease the thickness of the wafer 20 . Through this step, the wafer 20 is cut such that the thickness of the wafer 20 is minimized. Consequently, all of the conventional wafer processing facilities can be used at the following steps.
Furthermore, the size of the semiconductor package 1 is maintained at the level of the wafer 20 , and therefore, a light, thin, short, and small semiconductor package module can be manufactured.
The method of manufacturing the semiconductor package according to the present invention further includes a step of forming via holes through the wafer 20 from the rear surface of the wafer 20 to the pad electrodes 28 .
At this step, as shown in FIGS. 10A and 10B , the via holes 32 are formed at the wafer 20 where the pad electrodes 28 are disposed from the rear surface of the wafer 20 such that leads of the terminals 36 are redistributed on the rear surface of the wafer 20 at the level of the wafer 20 . The via holes 32 may be formed in two methods, one of which is to form the via holes 32 by laser. The other method is to form the via holes 32 by dry etching.
When the via holes 32 are formed by general laser, the quality of the via holes 32 formed through the silicon wafer 20 is very poor. Also, heat is generated during the laser process, by which other problems may occur. For this reason, the present invention uses a microwave photon beam.
As shown in FIGS. 10A and 10B , the via holes 32 are formed using a femtosecond (10 −15 second) laser within a very short period of time. As a result, the inner walls or the surfaces of the via holes 32 are smoothly processed.
When the via holes 32 are formed using the femtosecond laser, the via holes 32 may be formed through the pad electrodes 28 . Alternatively, the blind via holes 32 , the depth of which reaches the pas electrodes 28 , may be formed.
When the via holes 32 are formed using the dry etching, on the other hand, the via holes 32 are formed on the wafer 20 just once, and therefore, the mass production of the semiconductor package is easily accomplished. Using the dry etching process, the blind via holes 32 , the depth of which reaches the pad electrodes 28 , may be formed, as shown in FIG. 10A , or the via holes 32 may be formed through the pad electrodes 28 , i.e., the through via holes 32 may be obtained, as shown in FIG. 10B . However, a process of forming the blind via holes 32 , which are not formed through the pad electrodes 28 but the depth of which reaches the pad electrodes 28 , will be described hereinafter in detail.
The method of manufacturing the semiconductor package according to the present invention further includes a step of forming the terminals 36 electrically connected to the pad electrodes 28 in the via holes 32 .
At the step of forming the terminals 36 , a metal layer 42 is coated on the inner walls and the bottoms of the respective via holes 32 , the depth of which reaches the pad electrodes 28 of the wafer 20 , and the rear surface of the wafer 20 . The metal layer 42 may be formed in various different fashions. For example, the metal layer 42 may be formed only by sputtering, as shown in FIGS. 11A and 11B . Alternatively, the metal layer 42 may be formed by sputtering and electric plating, as shown in FIGS. 12A and 12B .
The sputtering process may be performed using a source material, such as titanium (Ti), titanium nitride (TiN), or copper (Cu), and then the electric plating process using copper (Cu), i.e., the Cu electric plating process may be performed. According to the present invention, however, only the sputtering process is performed to form a multilayered metal layer, for example, a three-layered metal layer or a four-layered metal layer, within a short period of time, as shown in FIGS. 11A and 11B .
It takes approximately 67 minutes to plate the metal layer 42 , the thickness of which is 5 micron, on the inner walls and the bottoms of the respective via holes 32 using the Cu electric plating process. Using the sputtering process according to the present invention, however, it only takes a few minutes to form the metal layer 42 . Especially, the metal layer 42 formed by the above-mentioned sputtering process includes an adhesion layer, a barrier layer, a solder wettable layer in addition to a tantalum (Ta) layer, a tantalum nitride (TaN) layer, or a copper (Cu) layer, although the thickness of the metal layer 42 is very small. Consequently, the metal layer 42 serves as a barrier for preventing diffusion of the copper (Cu), and therefore, good results are obtained.
The sputtering coating process and electric plating process may be simultaneously performed as follows. As shown in FIGS. 12A and 12B , the via holes 32 are completely filled with metal by a full-fill plating process. However, it takes too much time to perform the full-fill plating process, and therefore, several attempts to reduce the time necessary to perform the full-fill plating process are being made. Alternatively, metal balls (not shown) may be placed at the upper parts of the via holes 32 , and then the metal balls may be melted such that molten metal balls can be filled in the respective via holes 32 .
According to the present invention, seed metal is formed at a predetermined region of the wafer 20 , including the via holes 32 , by sputtering at the level of wafer 20 , and the respective via holes 32 is filled with conductive paste 46 by a metal printing process using a metal mask, in addition to formation of the metal layer 42 using only the sputtering process. This process enables the conductive paste 46 to be easily filled in the via holes 32 , and therefore, mass productivity is increased.
According to the present invention, the metal layer 42 may be formed at the via holes 32 by sputtering, and then insulating material may be filled in the via holes 32 to protect the metal layer 42 . The insulating material may be benzocyclobutene (BCB), polyimide (PI), or epoxy, which has low thermal expansion, high resistance to humidity, and excellent reliability.
The method of manufacturing the semiconductor package according to the present invention further includes a step of forming the circuit 26 at the rear surface of the wafer 20 , which is performed after the completion of the step of forming the terminals 36 .
At the step of forming the circuit 26 , normal photosensitive resist is applied to the metal layer 42 , and the circuit 26 is exposed using a mask, unnecessary parts are removed, and the metal layer 42 is etched to obtain the circuit 26 .
In the present invention, however, liquid-state photosensitive resist 50 is not used to form the terminal circuit 26 , as shown in FIGS. 13A and 13B . According to the present invention, photosensitive film resist 52 is used to prevent the metal layer 42 coated on the inner walls and the bottoms of the via holes 32 from being etched and to prevent the via holes 32 from being contaminated due to foreign matter, as shown in FIGS. 13C and 13D .
The method of manufacturing the semiconductor package according to the present invention further includes a step of coating a protective layer 56 to protect the circuit 26 . At this step, the circuit 26 is protected, and a positioning process for locating solder balls of the bump electrodes 30 is also performed.
At this step, the protective layer 56 is coated, an exposure process using a mask is performed to make the circuit 26 for locating the solder balls of the bump electrodes 30 , unnecessary parts of the protective layer are removed, and a post hardening process is performed. Preferably, the protective layer for protecting the terminal circuit 26 may be made of a material, such as benzocyclobutene (BCB), polyimide (PI), or epoxy.
According to the present invention, the interiors of the via holes 32 are filled with protective film resist 60 , as shown in FIG. 14A . Alternatively, the via holes 32 may be exposed in empty states.
In the process as shown in FIG. 14A , it is important to fill the via holes 32 with the protective film resist 60 and form the protective layer 56 having uniform thickness at the surface of the wafer 20 .
At this step, as shown in FIG. 14B , the protective layer 56 is coated when the via holes 32 is filled with the conductive paste 46 .
The method of manufacturing the semiconductor package according to the present invention further includes a step of forming the bump electrodes 30 on the terminals 36 .
At this step, as shown in FIG. 15 , the bump electrodes 30 , each of which is composed of a solder ball, are formed. Solder ball forming methods are classified into a method of attaching the bump electrodes 30 to the metal layer 42 , which constitute the terminals, a method of printing the solder paste, a method of forming the solder balls by sputtering, and a method of forming the solder balls by jetting. However, the important thing in this step is how much the manufacturing costs can be reduced and how much the quality and the reliability of the product can be improved.
When the bump electrodes 30 are made by the printing process, for example, the mask may be used in the case that the pitch of the solder balls is large, and the photosensitive film resist may be used in the case that the pitch of the solder balls is small.
As electronic equipment becomes lighter, thinner, shorter, and smaller, the pitch of the solder balls becomes smaller. Consequently, photosensitive film resist is preferably used.
Finally, the method of manufacturing the semiconductor package according to the present invention further includes a step of cutting a semiconductor package wafer 70 manufactured through the above-mentioned steps into a plurality of semiconductor packages 1 .
At this cutting step, as shown in FIG. 16A , the semiconductor package wafer 70 manufactured at the level of the wafer through the above-mentioned steps is diced into the plurality of semiconductor packages 1 . As shown in FIG. 16B , each of the diced semiconductor packages 1 has the bump electrodes 30 formed at the rear surface thereof. Consequently, each of the semiconductor packages 1 can be easily assembled through a general reflow process at the step of assembling a camera module, and therefore, several steps may be omitted when the camera module is manufactured.
For example, the semiconductor package 1 according to the present invention includes the image sensor 22 and the IR filter 10 , which are integrally attached to the semiconductor package 1 . Consequently, steps of preparing the IR filter 10 , such as a step of cutting the IR filter 10 , a step of inspecting the cut IR filter 10 , a bonding agent applying step, a step of attaching the IR filter 10 , and an ultraviolet (UV) hardening step, may be removed or omitted.
Using the method of manufacturing the semiconductor package according to the present invention, the IR filter 10 can be attached to the wafer 20 , while the level of the wafer 20 is maintained, to manufacture the semiconductor package 1 . Consequently, the process of assembling the camera module is considerably simplified, the mass production of the semiconductor package is accomplished, and the manufacturing costs of the semiconductor package are reduced.
As apparent from the above description, the IR filter is attached to the semiconductor package. Consequently, the present invention has the effect of minimizing the size of the camera module, accomplishing the mass production of the semiconductor package, and reducing the manufacturing costs of the semiconductor package.
Furthermore, the semiconductor package is manufactured while the bump electrodes are previously formed at the rear surface of the semiconductor package. As a result, the semiconductor package can be easily mounted through a generalized reflow process when the semiconductor package is mounted to the printed circuit board of the camera module. Consequently, the present invention has the effect of improving the productivity when the camera module is manufactured.
Moreover, the present invention enables the chip-on-package (CSP) mode manufacturing process to be considerably shortened. In addition, no additional IR filter is attached to the camera module. Consequently, the present invention has the effect of improving the manufacturing steps and thus improving productivity. Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | Disclosed herein are a semiconductor package used in digital optical instruments and a method of manufacturing the same. The semiconductor package comprises a wafer made of a silicon material and having pad electrodes formed at one side surface thereof, an IR filter attached on the pad electrodes of the wafer by means of a bonding agent, terminals electrically connected to the pad electrodes, respectively, in via holes formed at the other side surface of the wafer, which is opposite to the pad electrodes, and bump electrodes, each of which is connected to one side of each of the terminals. The present invention is capable of minimizing the size of a semiconductor package having an image sensor, which is referred to as a complementary metal oxide semiconductor (CMOS) or a charge coupled device (CCD), through the application of a wafer level package technology, thereby reducing the manufacturing costs of the semiconductor package and accomplishing production on a large scale. | 7 |
OBJECT OF THE INVENTION
[0001] The object of the present Invention is an improved device for welding by resistance that comprises significant innovations and advantages compared to the present fixtures and devices for resistance welding of small metallic parts and similar objects.
[0002] More specifically the new invention refers to a fixture that has an electrode for the welding of small parts and similar objects in transfer machines or rotating presses amongst other applications. The device is made up of a movable electrode in a support assisted by a gas cylinder, spring or compression element, allowing the time lapse of the weld to be sufficiently longs so that it is effective, without altering the movement cycle of the press in which it is installed. This device is held in place by a fast acting clamp and works in coordination with a conventional electrode arranged in the lower die or matrix. The device can also be used in multi-use clamps of robots and other machines.
BACKGROUND TO THE INVENTION
[0003] The welding of small metal parts by resistance is used in many different industries. It is applicable for the surface joining of parts and in the welding of plate-like elements to be bonded together.
[0004] The classical welding operation consists of placing two parts between two electrodes applying pressure with a specific force at the moment of passing a defined electrical current for a specific time between the two electrodes. The considerable resistance that exists between the surfaces in contact with the two parts and the high current that passes produces a high degree of heat that melts the surrounding material, thus making the weld.
[0005] In many cases two parts of differing sizes are welded, such as a nut onto the surface of a sheet of a certain size. The large part is usually positioned below and the small one is loaded by hand, by means of shuttles or pistons, onto the large part prior to applying of the pressure with the electrodes to both parts and welding.
[0006] In this method of welding the time parameters for the circulation of the electrical current and the pressures exercised by the electrodes onto the parts to be welded are important.
[0007] In turn in the case of wanting to introduce a welding step in a progressive machine press or in a transfer station, this must be carried out at the end of the process and not in an intermediate position, as would be the most logical. This is due to the fact that during the pressing cycle a pair of electrodes facing each other is not in a position to be able to carry out the resistance for the time necessary with the correct pressure. This problem is commonly solved by means of fixing the parts to be joined by means of a rivet or something similar. In effect the riveting operation is adapted to the rising and falling cycle of the dies in a progressive press; however a rivet has low resistance to the traction and zero resistance to the torsion.
DESCRIPTION OF THE INVENTION
[0008] The improved device for welding by resistance that is the purpose of this invention is characterised in that it includes a two part electrode assembly that form a clamp and allow it to work as an intermediary welding step in a progressive press machine or transfer stamping machine or automated drawing. However, the use of said device in the clamps of robots and other mechanisms suitable for its use is not dismissed.
[0009] The device mainly seeks to obtain two advantages, consistent with the obtaining of sufficient welding pressure for an exact time without the pressing cycle being altered with stoppages in order to carry out said weld and the automatic placing of the parts to be welded onto the sheet or plate that is being pressed or deep drawn.
[0010] In effect the device forms a welding assembly together with another electrode holding the parts to be welded and that allows the circulation of the welding current through it. Each one of the electrodes is fixed in one of the dies or die holders that face each other in the press.
[0011] The device is made up of a base body that is fixed to the die or die holder; said body has one or several parallel columns, even though in principle the case put forward has two columns, the electrode being movable on one of the said columns and the intermediate coupling element of the positioning device being on the other. Said electrode is forced by means of a rear expanding element, such as a spring or gas cylinder. The point of the electrode is housed on the inside of a ceramic positioning body with a floatingly supported on the other column. At the end of this body there is the small part to be welded (for example a bolt) held in place for the welding and facing a lower window. When the machine descends the positioning device makes contact with the lower part (for example a sheet onto which the nut is to be fitted) compressing it against the lower electrode. Said positioning device places the window by which the nut or the part to be welded will exit directly onto the surface of the lower part in its correct position. The continuation of the compression makes the point of the electrode advance through the body that holds the nut, approaching towards the nut and supported in the stated rear expansion element. When the advance of the press compresses the electrode against the nut or the part to be welded it moves it from its position against the lower sheet and said expansion element applies sufficient pressure between the parts to be welded in order to make the weld by the passing of the current. When the press withdraws, the electrode is withdrawn first and subsequently the positioning device, the two parts (sheet and nut) being duly welded and joined.
[0012] This device is designed to make the weld in a very short period of time; correspondingly the electrode is pressed against the part with enough force according to the measurement of the rear expansion element. In order to do this it has been arranged so that the welding current supply element works at high intensity and high frequency
[0013] The electrode has a base with a through opening over the column onto which it is arranged. Between the opening or housing for the electrode guide and the column there is a sliding insulating shield, for example made from a ceramic material or something similar. Said electrode has the corresponding electrical connecting cable at its rear end and on the front a rod corresponding to the internal part of same, which makes contact with the part to be welded and with the rear expansion element. The electrode body is cooled by water through an internal channel. In turn, the axial rod is by preference cooled by air through some openings or grooves around which forced air can be circulated, for example, for the purpose of avoiding the spilling of liquids onto the die. It has also been provisioned for the case in which under extreme use where a lot of heat is produced in the electrode that all the cooling is carried out by liquid, be it with water or suitable cooling liquids. The rod is connected to the electrode body in a permanent or in a movable manner, either by a Morse taper, a cylindrical anchorage or some other similar means of assembly.
[0014] The positioning device fulfils two basic approaches, it must locate the small part in the appropriate place for the welding and it must house the sliding electrode rod. Taking into account that said electrode obviously heats up, this positioning device is manufactured from a material that is resistant to the temperature and moreover has electrical insulation around the electrode, such as a ceramic material or similar. On the bottom part of the positioning device there is an exit window for the small part to be welded, and this must have suitable dimensions. On one side there is a window that connects to a conduit through which the parts are fed automatically, with a front sensor that will determine when the part has been placed in its position in order to start the welding process or the lowering of the press. The part is held until the electrode rod pushes it towards the distal window by means of some lateral clamps or a similar system.
[0015] The connection of the positioning device on the column on which it moves is carried out by means of an intermediate coupling part. Said part is also used for support at the entrance of the part supply conduit and the automatic regulator for the entry. Between this coupling part and the column there is an expansion element that determines the pressure to detach the body of the upper part respectively. The column has a hollow interior in which there is a spring or an opposing expansion cylinder in the core of the coupling part. In turn, the coupling part has a pivot, or support limiting the travel, housed in a side groove of the column for the purpose of preventing turning and limiting the maximum travel. It has been provisioned that between the column and the coupling part there is a casing or insulating and anti-friction element.
[0016] The entire assembly is fixed to the die by means of a system of fast connections, such as with some clamps or similar that are easily dismantled.
[0017] As the device is envisaged to be used in a completely automatic manner and without assistance it can have several sensors, such as the stated sensor for the presence of the small part to be welded on the inside of the positioning device, or the automated device for the supply of the parts at the entry of the conduit, amongst others.
[0018] In order to complete the description that is going to be made next and for the purpose of making the characteristics easier to understand, attached to this present document is a set of drawings in which, by way of being illustrative but not limiting, the most significant details of the invention have been represented.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 . Shows a partially sectioned elevation view of the device.,
[0020] FIG. 2 . Shows an elevation view of the electrode support column.
[0021] FIG. 3 . Shows a semi-sectioned elevation view of the column that supports the intermediary coupling part.
[0022] FIG. 4 . Shows a lower view of the intermediary coupling part.
[0023] FIG. 5 . Shows a sectioned elevation view of the intermediary coupling part.
[0024] FIG. 6 . Shows a transversally sectioned elevation view of the intermediary coupling part.
[0025] FIG. 7 . Shows a plan view of the electrode body.
[0026] FIG. 8 . Shows a sectioned elevation view of the electrode body.
[0027] FIG. 9 . Shows a sectioned elevation view of the positioning device.
[0028] FIG. 10 . Shows a transversal sectioned view of the positioning device.
[0029] FIG. 11 . Shows an elevation view of the electrode rod.
[0030] FIG. 12 . Shows a sectioned elevation view of the electrode rod, showing the channels for the passage of air.
[0031] FIG. 13 . Shows a transversal sectioned view of the electrode rod, showing the channels for the passage of air.
[0032] FIG. 14 . Shows a semi-sectioned view of a detail of welding with the part to be welded pressed by the rod against the sheet to be welded and in a slightly forward position.
DESCRIPTION OF A PREFERRED EMBODIMENT
[0033] In view of the figures commented on, and according to the numbering adopted, a preferred embodiment of the invention can be seen in same that is not by way of limitation. These consist of a support body ( 1 ) with two parallel columns ( 3 and 4 ), between which there is an expansion element ( 11 ) arranged in parallel. This body ( 1 ) has a receiving plate ( 2 ) at its rear and on both sides some bevelling for the fixing by means of clamps ( 24 ) or similar. On the column ( 3 ) there is an electrode ( 5 and 6 ) that is made up of a body ( 5 ) with a fixing opening with a movable insulated casing ( 10 ). The body ( 5 ) of the electrode has an anchoring ( 9 ) at one end to the connection cable to the electrical welding energy supply (not shown) and at the other end a rod ( 6 ) lowering by pressure. On the inside of the electrode body ( 5 ) there is a circuit ( 7 ) for the passage of the cooling liquid with its corresponding entrance ( 8 ) and exit. In turn the rod ( 6 ) has a series of openings and grooves ( 29 ) for the passage of cooling air. Said rod ( 6 ) is arranged coaxially with the expansion element ( 11 ) in the support body ( 1 ) and partially housed in the internal axial opening ( 13 ) of the positioning device ( 12 ). On the other column ( 4 ) there is an intermediary coupling part ( 19 ). At the end of said column ( 4 ) there is a blind opening ( 30 ), in which there is a spring ( 25 ) or an expansion element forced against said coupling part ( 19 ). In turn, on the side of the column ( 4 ) there is a groove ( 26 ) for the movement of a pivot ( 27 ) present on the coupling part ( 19 ), suitable to set the limit of the movement relative to each other. This moving part ( 19 ) has a rapid fixing pin ( 23 ) on the side of the bolt supply conduit ( 18 ) in its housing and at the front a housing space for the positioning device ( 12 ). Said positioning device ( 12 ) is in turn fixed by means of a second pin ( 22 ). The coupling part ( 19 ) has a moving casing ( 20 ) for fixing to the column ( 14 ).
[0034] The positioning element ( 12 ) has an internal axial opening ( 13 ) in which the electrode rod ( 6 ) is housed and into which the small part ( 31 ) to be welded is received from a side window ( 15 ) inserted into the passage ( 17 ) of the conduit ( 18 ). On both sides of the axial opening ( 13 ) of the positioning device ( 12 ), and at the entrance of the window ( 15 ) of the conduit ( 18 ) there are some windows in which there are two fixing clamps ( 16 ) protruding from the small part ( 31 ) when it enters from said conduit ( 18 ). The axial opening ( 13 ) has an exit window ( 14 ) for the small part ( 31 ) to be welded at its lower end that is pushed by the electrode rod ( 6 ) against the sheet to be joined ( 32 ), together with the lower electrode ( 28 ). On one side of the positioning part. ( 12 ), the coupling part ( 19 ) has an associated sensor ( 21 ) fitted to detect the presence of the part ( 31 ) for automation purposes. | IMPROVED RESISTANCE WELDING DEVICE that includes a mobile electrode in a support assisted by a spring, gas cylinder or expansion element, allowing its movement on being compressed so that the time lapse for the welding is sufficiently long to be effective, without altering the movement cycle of the press into which it is installed. The support has one or several columns, the electrode being supported sliding along one and with a rod housed on the inside of a positioning device, also axially movable, into which the small parts to be welded are received through a conduit. The positioning device, made from an insulated material, preferably ceramic, has some fixing clamps for said part until the welding is made pushed by the electrode rod through a lower window. | 1 |
BACKGROUND
[0001] In subsurface production efforts, a pump (e.g., Electric Submersible Pump or Progressive Cavity Pump) is generally used to bring a liquid (e.g., oil) to the surface. Specifically, a pump in a production well will pull the liquid (in some cases the pump carries mostly water, but the desired “product” can be minerals or gas, and can be produced with other means) into tubing that carries the liquid to the surface. The pump cannot discriminate between the liquid, and other material (e.g., sand, dirt, rocks) that may also be pulled into the tubing. When gas enters the tubing or when liquid level drops in the annulus from which it is being pumped, the lack of fluid in the tubing creates a cavity or void (e.g., cavitation or gas lock or vapor lock in the pump). This condition caused by gas or low fluid level can cause damage to the pump based on the frequency and duration of its occurrence.
SUMMARY
[0002] According to one embodiment, a system to identify a condition of cavitation or gas lock in a pump configured to convey a liquid to a surface from a subsurface environment via tubing includes a tool configured to create a binary event based on the condition, the binary event representing a change in state of a parameter; a sensor configured to detect the binary event based on the parameter; and a processor configured to process output from the sensor to identify the condition.
[0003] According to another embodiment, a method of identifying a condition of cavitation or gas lock in a pump configured to convey a liquid to a surface from a subsurface environment via tubing includes creating, using a tool in the subsurface environment, a binary event based on the condition, the binary event representing a change in state of a parameter; detecting, using a sensor, the binary event based on the parameter; and processing, using a processor, an output from the sensor to identify the condition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Referring now to the drawings wherein like elements are numbered alike in the several Figures:
[0005] FIG. 1 is a block diagram of a system to identify a cavitation condition according to embodiments of the invention;
[0006] FIG. 2 is a cross sectional block diagram of a system to identify cavitation in tubing according to an exemplary embodiment; and
[0007] FIG. 3 is a process flow of a method of identifying cavitation in tubing according to an exemplary embodiment of the invention.
DETAILED DESCRIPTION
[0008] As noted above, cavitation in the production tubing can result in damage to the pump. Thus, awareness of the condition can aid in extending the useful life of the pump. Currently, flow rate of liquid (e.g., oil) production at the surface is monitored. This monitoring allows an operator to identify when flow rate has dropped and further investigate whether the drop in flow rate is due to cavitation. However, a change in flow rate or a particular value of the flow rate is not dispositive, and the analysis and investigation needed to make a determination may require the pump to be shut off. Embodiments of the systems and methods described herein relate to a sensor identifying cavitation in the tubing based on a dispositive or binary event.
[0009] As used in the present application, “binary event” refers to an event that indicates an objective and discernable switch or change in state of a parameter. The exemplary binary event detailed below is a change from positive to negative pressure (pressure to no pressure) for fluid flow of liquid being pumped to the surface. That is, the exemplary binary event is a switch in state of the exemplary parameter of pressure. The exemplary embodiment detailed herein relates to a diverter whose operation results in a switch in pressure (from positive to negative) when cavitation occurs in the tubing. This binary event or switch in pressure in the particular embodiment can be detected by a sensor. Alternate embodiments contemplate a different downhole tool than the diverter causing a different dispositive or binary event based on cavitation and a different sensor identifying cavitation based on that binary event.
[0010] FIG. 1 is a block diagram of a system to identify a cavitation condition according to embodiments of the invention. Generally a tool 5 is disposed in a downhole environment 2 . The tool 5 creates a binary condition based on cavitation in tubing 20 . Although the tool 5 is shown in the tubing 20 , embodiments of the system may include the tool 5 being disposed on or outside the tubing 20 , as well. A sensor 6 identifies the binary event created by the tool 5 . A processing system 7 coupled to the sensor 6 processes the sensor 6 output to automatically take action or provide information to an operator.
[0011] FIG. 2 is a cross sectional block diagram of a system to identify cavitation in tubing 20 according to an exemplary embodiment. The exemplary embodiment relates to a pressure switch sensor 110 , which is an embodiment of the sensor 6 , identifying cavitation based on a switch in pressure caused by a diverter 120 , which is an embodiment of the tool 5 , during a cavitation condition. A subsurface environment 2 including a borehole 10 is shown below the earth's surface 1 . The borehole 10 may be cased and has tubing 20 disposed therein that may be production tubing, for example. The tubing 20 is comprised of sections of tubes with interfaces 30 between them. In the embodiment of the cavitation identification system discussed with reference to FIG. 1 , a diverter 120 , discussed further below, is disposed at an interface 30 of the tube sections, and sensor 110 is disposed in the flow of the tubing 20 at the surface 1 . The sensor 110 is coupled to a surface processing system 130 , which is an embodiment of the processing system 7 . The surface processing system 130 includes one or more processors 132 processing data based on instructions stored in one or more memory devices 134 and outputting the results through an output interface 136 . In addition to identifying cavitation based on data received from the sensor 110 , the surface processing system 130 may perform additional functions related to the production effort and may include additional components involved in that effort.
[0012] According to the embodiment shown in FIG. 1 , the diverter 120 is designed to divert debris such as rocks, sand, and dirt that are suspended in the fluid out of the (production) tubing 20 and into the annulus 15 between the (cased) borehole 10 and the tubing 20 when the pump 40 is turned off. However, when gas is in the tubing 20 or, for another reason, fluid levels drop in the tubing 20 , the diverter 120 according to one embodiment of the invention operates while the pump 40 is running. Under these conditions (pump 40 is on and diverter 120 is functional), any gas (and fluid) in the tubing 20 will be diverted out of the tubing 20 . When fluid levels are sufficiently low in the tubing 20 during this procedure, the diverter 120 operation causes pressure drop in the fluid flow and a vacuum is created at the diverter 120 causing fluid to flow in the opposite direction (drop toward the pump). At the pressure switch sensor 110 , this change in flow direction of the fluid is seen as a switch from pressure to no pressure (a binary event). As a result, the pressure switch sensor 110 need not be a sophisticated measurement device that measures flow or any particular parameter. The pressure switch sensor 110 may instead be a check valve that switches between on and off or a pressure valve that switches from positive to negative pressure to indicate that the cavitation condition has occurred in the tubing 20 . The surface processing system 130 coupled to the pressure switch sensor 110 may monitor a length of time that the condition lasts or a frequency of the condition over a period of time to take automatic action (e.g., shutoff of the pump 40 ). In alternate embodiments, the surface processing system 130 may provide the information indicated by the pressure switch sensor 110 to an operator through the output interface 136 so that the operator determines the action to take. According to the embodiment discussed with reference to FIG. 1 , the diverter 120 includes features described in U.S. Pat. No. 6,289,990. In alternate embodiments, the diverter 120 is another diverter that produces the vacuum and subsequent change in fluid flow direction when it operates while the pump is on during a cavitation condition.
[0013] FIG. 3 is a process flow of a method of identifying cavitation in tubing according to an exemplary embodiment of the invention. At block 310 , disposing a tool 5 along the tubing 20 includes disposing the diverter 120 at an interface 30 between tube sections, for example. The diverter 120 , according to the exemplary embodiment described above, diverts gas while the pump is on such that a vacuum is created. At block 320 , positioning a sensor 6 to sense a binary event created by the tool 5 includes positioning the pressure switch sensor 110 at the surface 1 in the flow of the tubing 20 . As noted above, the pressure switch sensor 110 according to the exemplary embodiment described above may be a check valve or pressure valve. Processing the sensor 5 output, at block 330 , includes processing system 7 (e.g., surface processing system 130 ) providing the indication of a cavitation condition to an operator. Alternatively, processing the sensor 5 (pressure switch sensor 110 ) output includes monitoring the frequency or duration or both of the cavitation condition to determine an action such as, for example, shutting down or slowing down the pump 40 .
[0014] While one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. | A system and method to identify a condition of cavitation or gas lock in a pump configured to convey a liquid to a surface from a subsurface environment via tubing are described. The system includes a tool to create a binary event based on the condition, the binary event representing a change in state of a parameter. The system also includes a sensor to detect the binary event based on the parameter, and a processor to process output from the sensor to identify the condition. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for evening the sliver produced by a card, wherein conventionally a determined output rate and a determined draft is set; the actual sliver weight for a given sliver length is determined by weighing and in case of a deviation from a desired sliver weight, the draft (tension) is varied to correspond to a predetermined desired sliver thickness.
According to a known process, in case of predetermined output rate and draft, the sliver number is determined by monitoring weight measurements while sliver regulation is deactivated. By virtue of a subsequent alteration of the draft the difference between the determined (actual) sliver number and the desired sliver number may be reduced. The thus resulting change in the sliver number is verified by renewed weighing. This process is repeated as often as necessary to achieve a sufficient agreement between the desired sliver number and the measured sliver number. Subsequently, the desired sliver thickness value is determined by potentiometer balancing.
In the sliver manufacture it is an objective to produce a sliver having a determined sliver number which should remain substantially constant. According to the known process at the beginning of the manufacture a determined output rate (m/min) and a determined draft (for example, 80-fold) are set. Subsequently, a determined sliver length is sampled and weighed (first monitoring weighing) from which the actual sliver weight (g/m) and thus the actual sliver number (m/g) is obtained. In case of a deviation from the desired sliver number the draft is changed by altering the feed roller speed whereby the quantity of the fiber material supplied to the carding machine is changed. Thereafter a second monitoring weighing is performed. In case the actual sliver weight then corresponds to the desired sliver weight (that is, the actual sliver number is identical to the desired sliver number), the desired sliver thickness may be determined which is utilized as a desired value for setting a sliver regulating device. Since there is a relationship between the sliver thickness and the sliver number dependent upon the fiber material, the desired sliver thickness corresponding to the desired sliver number may be derived from such relationship. The above-described prior art method is disadvantageously complex.
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 with which particularly the desired sliver thickness values may be determined in a simple manner.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, during a predetermined time period the actual sliver thickness is measured at the card output; the measured values are converted into an electric signal and combined into an average value for the actual sliver thickness, stored and applied to a computer. Further, a signal representing the actual sliver weight is applied to the computer which determines--from the relationship between the actual sliver weight and the actual sliver thickness--a desired sliver thickness corresponding to a desired sliver weight.
By virtue of the invention, a desired sliver thickness value may be determined in a simple manner. The method merely requires the determination of the output rate and the inputting of the desired sliver number and the actual sliver number determined from the monitoring weighing.
Preferably, the method according to the invention is used in a card sliver regulating system wherein at the output of the card the actual sliver thickness is measured, the measured value is transformed into an electric signal by a transducer and applied to a regulating device which in case of a deviation from a predetermined desired sliver thickness changes the rpm of the drive motor of a setting member, for example, the feed roller or doffer of the carding machine. In order to achieve an automatic setting of the desired sliver thickness value at the regulating device, the latter sets the rpm of the drive motor to a temporary desired value for the sliver thickness. Thereafter, there is determined a desired sliver thickness corresponding to the desired sliver weight and corrected based on the actual sliver weight and the actual sliver thickness and the desired value setter of the regulating device is set according to the corrected desired sliver thickness.
The given magnitudes are the desired output rate and a desired sliver number which are inputted in a computer. Initially, the draft is arbitrary. Starting from a functional relationship between the sliver number and sliver thickness the apparatus determines the corresponding desired sliver thickness value. By virtue of a comparison of the measured sliver thickness value and the desired value, by means of a regulating device (or manually) at constant output rate the actual sliver thickness value may be adapted to the desired sliver thickness value. A possible setting magnitude is the rpm of the feed roller of the card. The resulting actual sliver number is verified by a monitoring weighing. If the weighing shows a difference between the desired and actual sliver numbers, the actual sliver number is inputted in the computer. This input is used to correct the desired sliver thickness value such that the sliver supplied by the carding machine has tee desired sliver number.
Preferably, the computer determines--from a stored, fiber material-related function between sliver weight and sliver thickness--the temporary desired value for the sliver thickness, corresponding to the desired sliver weight.
The apparatus according to the invention for performing the above-outlined method comprises a measuring member which is arranged at the card output, and which may be a sliver trumpet, for determining the actual sliver thickness. A transducer which receives thickness signals from the trumpet is connected with the drive motor of a roller, such as a feed roller or a doffer with the intermediary of a regulating device having a desired value setter. The apparatus is characterized n that the computer is connected to the measuring member for the actual sliver thickness by means of an integrating device and a memory and to an inputting device for the actual sliver weight. Preferably, the computer is connected with the desired value setter of the regulating device. The integrating device is preferably an R.C. member; and the memory is preferably a buffered memory. According to an advantageous feature of the invention, the inputting device receives signals from a weighing device connected to the inputting device. According to another advantageous feature of the invention, the computer combines the electric signals of the transducer corresponding to the actual sliver thickness and the combined signals are stored. From the actual sliver thickness and the actual sliver weight a desired sliver thickness is determined which serves for setting the desired value of the regulating device.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic side elevational view, with block diagram, of a preferred embodiment of the invention for regulating the feed roller speed.
FIG. 2 is a schematic side elevational view, with block diagram, of another preferred embodiment of the invention for regulating the doffer speed.
FIG. 3 is a diagram illustrating the sliver weight (or sliver number) as a function of the sliver thickness, determined while the sliver regulating device is idle.
FIG. 4 is a diagram illustrating the voltage of a plunger coil of a measuring element as a function of the sliver thickness, at the measuring location.
FIG. 5 is a diagram illustrating the sliver weight (or sliver number) as a function of the sliver thickness, determined while the sliver regulating device is operational.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIG. 1, there is illustrated therein a carding machine which may be an "EXACTACARD DK 3" model, manufactured by Tr/u/ tzschler GmbH & Co. KG, M/o/ nchengladbach, Federal Republic of Germany. The carding machine has a feed roller 1, a licker-in 2, a main carding cylinder 3, a doffer 4, a stripper roller 5, two crushing rollers 6 and 7, a web guiding element 8, a sliver trumpet 9 and two calender rollers 10, 11. The feed roller 1 is coupled with a drive motor which is associated with a motor regulator comprising an electronic tachogenerator 11a, an electronic motor regulator 12 (such as a "SIMOREG" model, manufactured by Siemens AG, Federal Republic of Germany) and a variable-speed motor 13 driving the feed roller 1. A desired value setter for the feed roller 1, for example, a potentiometer, is connected with the electronic motor regulator 12. The electronic tachogenerator 11a and the electronic motor regulator 12 are connected by means of a sliver regulating device 14 (which may be a "CORRECTACARD CCM" model, manufactured by Tr/u/ tzschler GmbH & Co. KG) with the elements for regulating the sliver gathered by the sliver trumpet 9. A measuring element, for example, the sliver trumpet 9 equipped with a mechanical sensor senses the fluctuations of the sliver thickness. A sliver trumpet with mechanical thickness sensor element is described, for example, in German Offenlegungsschrift (non-examined published application) 2,358,941. The thickness fluctuations of the sliver are converted in a transducer 15 into electric signals applied to the sliver regulating apparatus 14. In this manner the desired rpm of the feed roller 1 is continuously varied as a function of the thickness fluctuation of the sliver. By virtue of a corresponding alteration of the rpm of the feed roller 1, the quantity of fiber material supplied to the card is varied, resulting in a corresponding variation of the weight of the sliver.
The measuring member for the actual sliver thickness, that is, the sliver trumpet 9 is connected with a microcomputer 18 by means of an integrating device 16, such as an R.C. member and a memory 17. The computer 18 is coupled to an inputting device 19 for manual inputting of, for example, the actual sliver weight. Further, the computer 18 is connected with the regulating device 14 by means of a desired value setter 20.
In operation, the desired sliver number is manually inputted in the computer 18 (which is a microcomputer controlling the operation of the carding machine). At a given desired value, in conjunction with a fiber-specific characterizing value there may be determined, by means of the inputted calibrating values or a formula, the clearance width of the measuring trumpet 9 at which the zero balancing for the regulating system 14 is to be effected for the desired sliver number. The zero balancing for determining the desired sliver value is automatically performed under the control of the microcomputer 18. A time-wise limited test phase is started during which the actual sliver thickness is measured, integrated and stored. The sliver produced during the test phase is manually removed and weighed. From the result of the weighing and a length determination the actual sliver number may be established. This sliver number or the length and weight values of the sliver specimen are applied to the computer 18. If the desired sliver number deviates from the measured actual sliver number, the computer 18 calculates the correction for the zero balancing (desired value) and performs thereafter automatically a new zero balancing at the previously calculated point. Thereafter, the regulating device is activated. In this manner, a self-setting carding machine is obtained in which the setting of the desired sliver thickness is carried out in the above-described manner in order to obtain the desired sliver number.
Turning to FIG. 2, with the doffer 4 a motor regulating system is associated which includes an electronic tachogenerator 21, an electronic motor regulator 22 (such as a "SIMOREG" model manufactured by Siemens AG) and a motor 23 which drives the doffer 4 or components associated therewith (including, for example, a sliver coiler). The electronic motor regulator 22 comprises an rpm regulator with a subordinated current regulator. The load part is formed as a semi-controlled one-phase bridge. A desired value setter (such as a potentiometer) for the output rate which corresponds, for example, to the rpm of the doffer 4, is connected with the electronic motor regulator 22. German Offenlegungsschrift No. 2,944,428 describes the regulation of the feed roller 1 and the doffer 4 by means of an electronic motor regulating device 12 and 22, respectively.
The sliver trumpet 9 (sliver thickness measuring device) is connected by means of a transducer 15 with the card sliver regulating system 14 which in turn is connected with the motor regulator 22. Further, the sliver regulating system 14 is connected by means of a desired value setter 24 with a process control apparatus 25 such as a "TMS" model manufactured by Tr/u/ tzschler GmbH & Co. KG, with a microprocessor which may be a Rockwell model 6502. The process control apparatus 25 includes a microcomputer as well as an integrating device and a memory, which are shown in FIG. 1 at 18, 16 and 17, respectively. With the process control apparatus 25 there is connected an inputting and retrieving device 19. For an automatic operation, the inputting device 19 may be coupled with a weighing device 26 which determines automatically the actual sliver weight for a predetermined sliver length (testing phase) and applied the data to the process control apparatus 25.
Turning now to FIG. 3, there is graphically illustrated the determination of the desired sliver thickness according to the invention. Such determination is effected in the following steps:
(a) The regulating device 14 is switched off.
(b) At the beginning of the operation there is set with the potentiometer an output rate for the doffer 4, for example 200 m/min and an arbitrary draft, for example, an 80-fold draft at the potentiometer of the feed roller 1, whereby an arbitrary sliver thickness is set. The setting of the output rate and the draft are procedures known by themselves.
(c) The curve A of FIG. 3 is inputted in the memory of the computer 18. The curve A shows the relationship between sliver weight (or sliver number) and sliver thickness at the measuring location of the sliver trumpet 9. The curve A is fiber material-specific and had been determined empirically.
(d) The function between the voltage U of a plunger coil which is connected in the CORRECTACARD device with the sensor lever of the measuring trumpet 9 and the sliver thickness (clearance width) at the measuring location in the sliver trumpet 9 according to FIG. 4 is applied to the computer 18. This relationship serves for calibrating (zero balancing) the regulating device 14.
(e) The desired sliver number is applied to the computer 18 via the inputting device 19. Such sliver number may be, for example, N m =0.20 m/g (desired value).
(f) According to curve A to the desired sliver number N m =0.20 m/g there corresponds a provisional desired sliver thickness of d=2.5 mm. This thickness is determined by the computer 18.
(g) First zero balancing of the regulating device. To the provisional desired sliver thickness d=2.5 mm there corresponds according to FIG. 3 a voltage U=10V at the plunger coil of the transducer 15. Based on that voltage there is automatically set the sensor lever and thus the clearance d=2.5 mm in the sliver trumpet 9 by means of the plunger coil. In this manner there is automatically set, by means of the desired value setter 20 of the regulating device 14, the provisional desired sliver thickness d=2.5 mm determined by the computer 18 in the measuring trumpet 9. By virtue of the provisional desired sliver thickness there is first obtained an approximate value for the desired sliver number of 0.20
(h) Weighing check. The actual sliver number is determined by weighing; for example, N m =0.16 m/g (actual sliver number). This result indicates that the sliver is too heavy.
(i) Determination of the actual sliver thickness. For a predetermined sliver length (or a predetermined time period) the electric signals for the actual sliver thickness values are integrated at the measuring location in the sliver trumpet 9 and are thereafter stored and applied to the computer 18. The result is, for example, d=3.5 mm (actual sliver thickness).
(j) Computer. From the actual sliver number N m =0.16 m/g and the actual sliver thickness of d=3.5 mm the computer 18 generates a new curve B.
(k) From the curve B there is obtained for the desired sliver number a value N m =0.20 m/g, a corrected desired sliver thickness d corr =4.4 mm.
(1) Second zero balancing. The corrected desired sliver thickness d corr =4.4 mm is set in the regulating device 14 by means of the desired value setter 20. In this manner, the corrected desired sliver thickness is automatically set by the computer 18 at the sliver measuring trumpet 9.
(m) Thereafter, the regulating device 14 is switched on. At the desired sliver thickness d corr =4.4 mm the discharged sliver has the desired sliver number N m =0.20 m/g.
In the above-discussed method of the invention first the regulating device 14 has been disconnected as the operating person manually assumes the task of the regulating device 14.
The method according to the invention may be also performed while the regulating device 14 remains operational. The steps of the method in such a case are as follows:
(a) The regulating device is switched on.
(b) Initially there is set an output rate of, for example, 200 m/min at the potentiometer of the doffer 4 and an arbitrary draft, for example, an 80-fold draft at the potentiometer of the feed roller 1, whereby an arbitrary sliver thickness is obtained. The setting of the output rate and the draft by means of the potentiometer are procedures known by themselves.
(c) In a memory of the computer 18 the curve A of FIG. 5 is inputted. Curve A represents the relationship between the sliver weight (or sliver number) and the sliver thickness at the measuring location of the sliver trumpet 9. The curve is fiber material-specific and had been previously determined empirically.
(d) The function between the voltage U at the plunger coil which is connected in the CORRECTACARD device with the sensor lever of the measuring trumpet 9 and the sliver thickness (clearance width) at the measuring location in the sliver trumpet 9 is inputted in the computer 18 according to FIG. 4. This relationship serves for calibrating (zero balancing) the regulating device 14.
(e) The desired sliver number is applied to the computer 18 via the inputting device 19. Such sliver number may be, for example, N m =0.20 m/g (desired value).
(f) To the desired sliver number N m =0.20 m/g there corresponds according to curve A provisional desired sliver thickness of d=5 mm. This thickness is determined by the computer 18.
(g) First zero balancing of the regulating device. To the provisional desired sliver thickness d=5 mm there corresponds according to FIG. 5 a voltage U=10V at the plunger coil. Based on that voltage there is set automatically the rpm of the feed roller 1 by means of the regulating device. This automatically sets in the measuring trumpet 9, by means of the desired value setter 20 of the regulating device 14 the provisional desired sliver thickness d=5 mm determined by the computer 18. By virtue of setting the provisional desired sliver thickness there is obtained first an approximate value for the desired sliver number of 0.20.
(h) Weighing check. By weighing, the actual sliver number is determined which was found to be N m =0.15 m/g (actual sliver number). This value indicates that the sliver is too heavy.
(i) Computer. From the actual sliver number N m =0115 m/g and the actual sliver thickness d=5 mm the computer 18 generates a new curve B.
(j) From the curve B there is obtained for the desired sliver number N m =0.20 m/g a corrected desired sliver thickness d corr =4.0 mm.
(k) Second zero balancing. The corrected desired sliver thickness d corr =4.0 mm is set with the desired value setter 20 of the regulating device 14. In this manner there is automatically set the corrected desired sliver thickness (determined by the computer) in the regulating device 14.
The invention was described by way of an example for determining the actual sliver thickness in a sliver trumpet 9 with a mechanical thickness sensing. The invention may find application for all equivalent measuring values corresponding to the actual sliver thickness, for example, determination of the actual sliver mass, for example, by means of light irradiation, pneumatic measuring processes, weighing processes or scintillation counters.
The present disclosure relates to subject matter contained in Federal Republic of Germany Patent Application Nos. P 36 17 528.5 (filed May 24th, 1986) and P 37 03 450.2 (filed Feb. 5th, 1987) which are incorporated herein 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. | A method of evening a sliver produced by a carding machine in which a predetermined output rate and draft are set. The method includes the steps of determining the actual weight of a predetermined sliver length by weighing; determining the difference between the actual sliver weight and a desired sliver weight; as a function of the difference altering the draft corresponding to a predetermined sliver thickness; measuring momentary actual thicknesses of the running sliver at a card output for a determined time period or sliver length and generating mechanical signals representing the momentary actual sliver thicknesses; converting the mechanical signals to first electric signals; combining the first electric signals into a second electric signal constituting an average of the first electric signals and representing the actual sliver thickness of the measured sliver; storing the second electric signal; applying the second electric signal to a computer; applying to the computer a third electric signal representing the actual sliver weight; and determining, with the computer and from a function between the actual sliver weight and the actual sliver thickness, a desired sliver thickness corresponding to a desired sliver weight. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to cutting articles by use of a rotating axially moving tool and more particularly to cutting tools having a work-engaging structure and angled or stepped cutting edges. Still more particularly, the present invention relates to cutting plastic pipe to enable a lateral pipe to be replaced on a Y-connection, a T-connection or a 90° connection.
[0003] 2. Background information
[0004] The prior art discloses various tools and methods for cutting pipe.
[0005] U.S. Pat. No. 3,752, 592 to Fitzgerald, et al., for example, discloses a pipe reamer apparatus particularly for use with plastic pipe and a method of reaming plastic pipe fittings such as elbows or the like.
[0006] U.S. Pat. No. 3,872,748 to Bjalme, el al. discloses a tool for beveling plastic pipe in which the tool is carried in a slide inclined at the bevel angle and fed toward the pipe end as it is rotated about the axis of the pipe.
[0007] U.S. Pat. No. 4,483,222 to Davis discloses a device for removing pipe attached to a fitting includes cutting apparatus for removing the pipe disposed within the fitting. A wrench apparatus is connected to the cutting apparatus for gripping the fitting to prevent its movement when the cutting apparatus is activated. Alternatively, this device may be used as a reaming device which permits radial movement of the cutting blades into engagement with a pipe after the cutting blades have been inserted within the pipe.
[0008] U.S. Pat. No. 4,693,643 to Heyworth discloses a planing device which is operable for progressively planing or cutting the end of a plastic pipe to the desired length, or for reaming out a piece of plastic pipe fixed in a plastic pipe fitting in such a manner that the plastic pipe fitting can be reused. The pipe planing device is portable and is rotated by an electric drill or the like and includes a cylindrical pilot removably supported on radially spaced-apart spider-like cutter arms having cutter blades attached to their outer ends and extending outwardly beyond the cylindrical pilot distance which is equal to the thickness of the plastic pipe to be cut or reamed. The outer circumference of the cylindrical pilot is dimensioned to provide a snug rotatable fit within the end of the plastic pipe to be planed and operates to center the planing device along the longitudinal axis of the plastic pipe.
[0009] U.S. Pat. No. 4,975,001 to Rabo, et al. discloses a plastic pipe reboring tool having an elongated shank, a generally concave-convex cutting head, and changeable guide discs effective for cleaning residue glue and plastic from used plastic pipe and fittings so they can be used over again. The reboring tool is operational with both powered and manual chuck rotating devices and can be used on different sizes of plastic pipe.
[0010] U.S. Pat. No. 5,000,629 to Nygards discloses a self-centering plastic pipe router tool for routing of a sawed-off end of pipe from the interior surface of a salvageable pipe. The router tool is a disk with an axial shank on one side of the disk. A pair of cutting flanges extend radially outwardly and upwardly in the direction of the axial shank form the disk perimeter to form first and second cutting edges. A concentric cylindrical skirt extends downwardly form the disk for axial centering of the router tool within the waste pipe inner diameter. The first cutting edges are sized for routing of the waste pipe and second cutting edges are sized to plane and refinish the interior surface of the salvageable pipe for re-use.
[0011] U.S. Pat. No. 5,401,126 to Norris, et al. discloses a bit usable in combination with a rotatory diver, such as a drill, for extracting a remnant of a cut-off pipe from a pipe socket. The bit comprises a forward portion which is a pilot to keep the bit centered in the remnant and thereby centered in the pipe socket, a forward-facing ring cutter whose inner and outer diameters generally match the inner and out diameters of the pipe remnant being extracted, said ring cutter bing operable to cut and/or scrape the remnant edgewise form the socket, and a forward facing ring scraper operable to stop the bit from excessive penetration into the pipe socket and operable to scrape bonding material remnants form the end face of the pipe coupling.
[0012] In working with plastic pipe, a relatively common procedure involves replacing a lateral line which extends at a Y-connection, a T-connection or 90° connection at a at a main pipe line. This procedure is relatively time and labor intensive and an improved means of carrying this procedure out is needed.
BRIEF SUMMARY OF THE INVENTION
[0013] It is an object of the present invention to provide an improved apparatus and method for replacing a lateral line which extends from a Y-connection, a T-connection or a 90° connection at a main pipe line.
[0014] This and other objects are met by the present invention which is a tool for cutting a plastic pipe comprising a concave guide section having a central aperture. A plunger having a longitudinal axis extends through the central aperture and at least one blade extends in generally radial relation from the central axis inside the lower concave skirt section.
[0015] In another embodiment the present invention is a tool for cutting a plastic pipe comprising a concave guide section comprising a lower skirt comprising an upper generally horizontal member and a lower peripheral wall member. There is an aperture in said upper horizontal member and a tubular section having an upper and a lower terminal end and an interior axial passageway and is positioned at said lower terminal end such that said axial passageway is aligned with the central aperture of the generally horizontal member of the lower skirt section. A plunger comprising an upper rod having an upper and a lower terminal end and a spiring retaining structure adjacent said upper terminal end and is disposed in said axial passageway of the tubular member of the concave guide section in coaxial relation with said tubular member and is positioned such that said upper terminal end is elevated above the upper terminal end of the tubular member. A lower blade retaining structure is formed in which at least one blade having a distal edge extends in a generally radial direction such that said distal edge is positioned in spaced inward relation from the lower peripheral wall member of the concave guide section. A helical spring having an upper terminal end and a lower terminal end and coaxially overlaps the upper rod member and bears against the spring returning structure of the rod member at its upper end and bears against the upper terminal end of tubular member at its lower end.
[0016] Also encompassed by the present invention is a method for replacing a first lateral pipe with a second lateral pipe when the first lateral pipe is connected to a main pipe line by a Y-connection, a T-connection or a 90° connection. In this method the first lateral pipe is cut outwardly from the widened connection socket on the Y-connection, a T-connection or a 90° connection. A tool as is described above is then positioned reality to the widened connection section so that the inner surface of the concave guide section bears against the outer surface of widened lateral connecting section and distal edge of the blade bears against the first lateral pipe section. The plunger is then rotated about it longitudinal axis so that the blade cuts away at least part of the inner first lateral pipe section to form a pipe receiving space adjacent the widened connection socket. A second lateral pipe is then inserted end wise into the pipe receiving space to complete the procedure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention is further described with the reference to the accompanying drawings in which:
[0018] [0018]FIG. 1 is a cut-away front elevational view of a preferred embodiment of the pipe cutting tool of the present invention;
[0019] [0019]FIG. 2 is a bottom plan view of the pipe cutting tool shown in FIG. 1;
[0020] [0020]FIG. 3 is a schematic view of a lateral line extending from a main line in which illustrates a first step in a preferred embodiment of the method of the present invention;
[0021] [0021]FIG. 4 shows the pipe arrangement shown in FIG. 3 after attachment of the cutting tool shown in FIG. 1 to illustrate further steps in the preferred embodiment of the method of the present invention;
[0022] [0022]FIG. 5 is a bottom and front perspective view of a bit which may be used in an alternate embodiment of the cutting tool of the present invention;
[0023] [0023]FIG. 6 is a bottom and front perspective view of a guide section which may be used with the bit shown in FIG. 5 in an alternate embodiment of the cutting tool of the present invention;
[0024] [0024]FIG. 7 is a vertical cross-sectional view of an alternate embodiment of the cutting tool of the present invention using the bit shown in FIG. 6 and also show in conjunction with a Y-connection to illustrate a step in the method of the present invention;
[0025] [0025]FIG. 8 is a vertical cross-sectional view of the cutting tool shown in FIG. 7 in use on a Y-connection to show further steps in the method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Referring to FIGS. 1 and 2, the cutting tool of the present invention includes a guide section 10 which is made up of a tubular section 12 which has an upper terminal end 14 and a lower terminal end 16 and an axial bore 18 . The guide section 10 also includes a lower skirt section 20 which has a horizontal top made up of radial support members 24 , 26 and 28 with a central apeture 30 .
[0027] The lower skirt section 20 also includes a peripheral wall member 32 which has an inner side 34 and an outer side 36 with a plurality of apetures as at apeture 38 in this peripheral wall member 32 which allows operation of the tool to be monitored. The cutting tool also includes a plunger section 40 which has an upper rod 42 having a longitudinal axis 44 and an upper terminal end 46 and lower terminal end 46 . A pin 50 and washer 52 serve as a retaining member for a helical spring 54 , which is also retained at its lower end by the upper terminal end 14 of tubular member 12 of the guide section 10 . The plunger section 40 also includes a lower central blade support structure 56 from which blades as at blades 58 , 60 and 62 extend radially. These blades have respectively wedge shaped terminal cutting edges 64 , 66 and 68 . Blades 58 and 60 also have respectively upper outwardly extending steps 70 and 72 .
[0028] Referring to FIGS. 3 and 4, the method of using the using the tool described above to replace a lateral pipe extending from a Y-connection or T-connection is described. In these figures there is a Y-connection 76 with a horizontal section 78 having at its opposed ends widened pipe sockets 80 and 82 . Main line pipes 84 and 86 are connected respectively to the Y-connection 76 at the widened pipe sockets 80 and 82 . The Y-connection 76 also includes a lateral section 88 which has a terminal widened pipe socket 90 . A lateral pipe 92 is connected endwise to this widened pipe socket 90 and extends outwardly therefrom. In the first step of the method of this invention the lateral pipe 92 is cut slightly outwardly from the pipe socket 90 as is shown particularly in FIG. 3. Lateral pipe 92 is thereby divided into an inner lateral pipe section 94 which remains attached to the pipe socket 90 and an outer pipe lateral pipe section 96 which is removed. As is shown particularly in FIG. 4, in the next step of the method the tool shown in FIGS. 1 and 2 is positioned on the Y-connection 76 so that the blade edges as at 64 , 66 and 68 bear against the inner lateral pipe section 94 and the inner side 34 of the peripheral wall member 32 bears against the pipe socket 90 . The upper rod 42 of the plunger section 40 is then rotated about its longitudinal axis 44 so that the blades cut or abraid the inner lateral pipe section 94 until some or all of the pipe section 94 is removed so that a pipe receiving space is formed adjacent the pipe socket 90 . A new lateral pipe 92 is then inserted endwise into the pipe socket 90 to finalize the procedure.
[0029] Referring FIG. 5, there is shown a bit 98 which may be used in an alternate embodiment of the pipe cutter of the present invention. This bit 98 includes blades 100 , 102 , 104 , 106 , 108 and 110 . The bit 98 also includes a threaded bore 112 to allow attachment to a rod (not shown) similar to the one shown above. Each blade as, for example, blade 100 includes a lower section 114 which has a cutting edge 1 16 . There is also a lower step cutting edge 118 and an upper section 120 with a cutting edge 122 . Above cutting edge 122 there is an upper step cutting edge 123 .
[0030] Referring to FIG. 6, a guide section 124 which may be used in an alternative preferred embodiment is shown. This guide section 124 has a tubular member 126 with an axial bore 128 and a concave section 130 . This concave section 130 is comprised of a horizontal member 132 with a central aperture 134 and is connected by vertical supports 136 , 138 and a 140 to a lower skirt member 142 .
[0031] Referring to FIGS. 7 and 8, the method of use of the alternative preferred embodiment using the bit 98 shown in FIG. 5 and guide section 124 shown in FIG. 6 is illustrated. Here there is a Y-connection 142 similar to the structure described in FIGS. 3 and 4 which has a lateral section 144 with a widened pipe socket 146 . The first section of lateral pipe 148 which remains after the pipe has been cut in the way described above is fixed endwise in the widened pipe socket 146 . The alternate embodiment of the cutter is shown in FIG. 7 in an initial position axially aligned with widened pipe socket 146 and the first section of lateral pipe 148 . It will be observed that in addition to the features described above in the bit 98 and guide section 124 the tool has a plunger 158 which includes the rod 160 which is fitted with the threaded bore of the bit 98 . In this position a pin 162 which extends through apertures in the tubular section 126 and rod 158 folds the bit 98 in an upper position in the guide section 124 adjacent the horizontal member 132 . After the pin 162 is removed the rod 160 along with the bit 98 is moved forward to engage the first section of the lateral pipe with the blades as at blade 100 at the same time the skirt 140 outwardly engages the widened pipe socket 154 . The rod 160 is rotated about its longitudinal axis so that the blades as at blade 100 cut or abraid the first section of lateral pipe 156 to allow its removal, thus leaving a pipe receiving space adjacent the pipe socket 154 . In particular, it will be seen from FIG. 7 that pipe 148 is cut by cutting edges 116 and 118 . The tool is then removed from the widened pipe socket to allow a second lateral pipe (not shown) to be inserted endwise into the widened pipe socket 154 . It will also be appreciated that it would be possible to increase the inner diameter of a pipe. For example, it will be seen from FIG. 8 that the inner diameter of pipe 146 could be increased by means of cutting edge 123 with support being provided by cutting edge 122 .
[0032] Those skilled in the art will appreciate that the tool and method of its use described above on a Y-connection can easily be adapted to replace a lateral pipe connected to a T-connection or a 90° connection.
[0033] It will be appreciated that a tool and the method of its use has been described which allows for the efficient, quick and cost effective removal of a lateral pipe on a Y-connection, a T-connection or a 90° connection and its replacement with another lateral pipe to that connection.
[0034] In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.
[0035] Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described. | A tool for cutting a plastic pipe comprising a concave guide section having a central aperture; and a plunger having a longitudinal axis extending through the central aperture and at least one blade extending in generally radial relation from the central axis inside the concave guide section. | 1 |
BACKGROUND OF THE INVENTION
This invention pertains to a ceiling construction for a laminar flow clean room and more particularly to a membrane diffusion panel for uniformly distributing air flow through the clean room without turbulence.
The clean room industry was spawned in the early 1960's. The uniform mass air flow of HEPA (High Efficiency Particulate Absolute) filtered air was dubbed "laminar flow" because of the uniform velocity or non-turbulent (laminar) flow of air either vertically or horizontally across the work space. A typical clean room includes walls, floor, and ceiling, an air supply feeding a duct or plenum, a fan, a planar section of ceiling panels hung below the ceiling comprising HEPA filters, for filtering the air.
The advent of high tech developments in electronics, optics, telecommunications, robotics, medicine, and genetic engineering, to name a few, give rise to an ever growing need for "clean space" in manufacturing and research and development. The cleanest class of room according to federal standards is the class 100 clean room. The contamination level of clean air is generally proportional to the number of air changes per hour that is caused to move through the space. The higher the air exchange rate the cleaner the room, and the larger quantity of air filters required.
Over the last ten years inflation has given rise to the cost of Class 100 clean rooms to the point that they now install for an excess of $200.00 per square foot of work area. Thus efficient use of HEPA filters is necessary for cost efficient use of clean space. Turbulent distribution of air requires a greater number of air changes to achieve a given level of efficiency, wasting valuable filter use. Another reason that the systems are so costly is that the HEPA filters are suspended in the ceiling in an air tight framework. Along with this expensive framework must come a structural system to support the weight of the filters and a provision for the lighting system for the work space. A further disadvantage of the HEPA filtered air distribution system is that the induction of air at the ceiling causes aspiration at the filter face and turbulent air patterns develop adjacent to the HEPA filter and around that part of the ceiling that is occupied by lights and ceiling panels.
In U.S. Pat. No. 3,975,995 (Shuler) a ventilated ceiling construction is shown comprising a first planar surface spaced from the room ceiling, and having a mixed array of filter panels and blank panels, and a second planar section of perforated air diffusing panels spaced from and disposed below the first planar panel defining a clean air plenum therebetween. It has been found that a perforated sheet air diffuser is limited in its capacity to distribute air uniformly. In addition the Shuler system does not account for total elimination of turbulence. The membrane diffusion panel of the present invention is a substantial improvement over the perforated air diffusing panel of Shuler. Air is diffused evenly over the face of the membrane diffusion panel.
An additional patent of general relevance to the present invention is U.S. Pat. No. 4,461,205 (Shuler) which discloses a lighting and filtering unit for a clean room.
As can be seen from the above, in view of the expanding needs of the developing "clean space" industry an increasing need for cost effective quality air filtering exists.
SUMMARY OF THE INVENTION
The contamination level of clean space is generally proportional to the number of filtered air changes per hour that is caused to move through the space. The air exchange rate generally varies from a low of about 20 air changes per hour to a high of about 200 to 300 air changes per hour. The higher the air exchange rate the cleaner the room, and the larger the quantity of filters required in the ceiling. The present invention as shown in FIG. 2, is adapted to minimize the amount of air flow necessary to achieve desired contamination levels by providing uniform laminar flow without turbulence. In this way the number of air exchanges can be reduced for a given contamination level with consequent saving in filter costs and improved efficiency of the system.
The primary object of the present invention is to provide a structure for air filtering and distribution which takes advantage of the latest technology in materials and filter media to substantially reduce the cost and improve the performance of a vertical laminar flow clean room.
The present invention relates to the method of creating a uniform diffusion of air across the entire ceiling. By use of a translucent sheet which has controlled porosity (e.g. expanded polytetrafluoroethylene or spun bonded polyester) it is possible to fabricate a membrane panel that can be designed to lay into a conventional grid such as used to retain lay in acoustical tiles commonly used in ceilings of office buildings. The advantage of The "Membrane Diffusion" system provides that the lights for the enclosure be mounted above the ceiling thus eliminating the problem of "turbulent cones" which commonly occur when the lights are mounted below the diffused clean air ceiling. The translucent fiber sheets can be varied in pore size balancing the system to provide uniform distribution of air across the ceiling by replacing the panels in certain areas with panels of different pore size.
Applicant has discovered that, because the uniform diffusion of air across the entire ceiling of the room which is the result of the subject Membrane Diffusion Panels, the clean room can achieve much higher cleanliness levels for a given HEPA filtered air exchange rate than the conventional HEPA filtered ceiling without membrane diffusion panels. Thus the high cost of HEPA filters is reduced, making application of clean air techniques cost efficient in a wider variety of applications.
In a recent application of this technique, in a 1200 square foot clean room with 60% HEPA filtered ceiling, operating levels of better than Class 100 have been achieved. Without the Membrane Diffusion Panels an operating level of Class 5000 to 10,000 would normally be expected.
The applicant has also discovered that a slight pressure is developed in the sub-ceiling between the primary HEPA filter ceiling and the Membrane Diffusion ceiling in such a manner as to cause any leakage of air through the primary ceiling grid to be outward and away from the clean space. This has the advantage of allowing the primary grid to be installed in an inverted "T" bar grid without the use of gaskets or sealants around each grid opening surface. This advantage results in a very cost effective installation since standard commercial "T" bar grids can be used.
Applicant has further discovered that air turbulence may be minimized in the system provided by combining the aforenoted translucent membrane diffusion with lighting located in the primary ceiling, above the diffusion membrane.
The present invention provides an air filtering and distribution apparatus for use in an environmentally controlled atmosphere, which comprises a ceiling having a plurality of panels wherein at least one panel is an air filter; a translucent membrane diffusion system mounted substantially parallel to and below the ceiling, forming a plenum therebetween having controlled porosity to evenly distribute air across the face of the panel, the porosity being further controlled to resist air flow therethrough, the membrane diffusion system being comprised of a fibrous sheet mounted on a grid structure, and a means for introduing air into the plenum.
The noted objects and advantages are attained by the structure recited. These and other objects and advantages will become apparent from the following detailed description of the present invention which is to be taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the membrane diffusion panel of the present invention illustrating a first side which is assembled and a second side which is disassembled, the first and second sides having a common grid plate. A portion of the grid plate is not shown and the perimeter thereof is illustrated by dotted lines.
FIG. 2 is a section view of a clean room employing the structual elements of the present invention.
FIG. 3 is a section view of an alternate embodiment of a clean room employing the elements of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the membrane diffusion panel 10 of the present invention comprises ceiling panel 12, preferably a polystyrene ceiling panel comprising 70 to 80 percent open area. Ceiling panel 12 is preferably translucent to allow lighting fixtures affixed thereabove to provide adequate illumination for the clean air work area. As shown in FIG. 1, ceiling panel 12 may take the form of a grid having substantially parallel longitudinal and lateral bars defining apertures therebetween. A fiber sheet 14 is mounted onto ceiling panel 12. Retainer clips 16 preferably composed of an extruded plastic secure fiber sheet 14 to ceiling panel 12 to comprise the membrane diffusion panel 10.
Fiber sheet 14 includes a clip 18 along its edges to provide assurance against unfiltered air leaking past the edges of the fiber sheet. Fiber sheet 14 preferably comprises a translucent spunbound polyester structure of continuous filament polyester fibers. The "Reemay" spunbound polyester sheet by DuPont may be used. The spunbound fibers of fiber sheet 14 are bound in a manner to achieve a predetermined pore size for passage of air therethrough. Membrane diffusion panels 10 may be fabricated to lay in a conventional grid such as those commonly used to retain lay in acoustical tiles. Fiber sheets 14 of varying pore size may be used to provide balanced and uniform distribution of air across the ceiling by replacing the membrane diffusion panels 10 in certain areas with panels of different pore size. Fiber sheet 14 and ceiling panel 12, act in combination to uniformly distribute air through the work space.
Referring now to FIG. 2, we see a front cut away view of a clean room 22. The clean room air circulation system generally comprises a return unit 24, ductwork 26, an optional filter 28, and fan 30. The ceiling structure comprises ceiling 32, first grid 34, and second grid 36, hangers 38 are hung from ceiling 32 to support the first and second grids.
Diffusion panels 10 are held by I-clamps which are hung from the primary grid. Air flow through the membrane diffusion panel 10 undergoes a change of pressure of 0.01 inches of water at 100 feet per minute face velocity. During operation a slight pressure is developed in the sub-ceiling between the first grid 34 and the second grid 36 causing any leakage of air through the primary ceiling grid to be outward and away from the clean space. Thus the first grid may be installed on inverted T-bar grids without the use of gaskets or sealants around each grid opening surface.
The first grid is composed of a variety of components as desired. In the embodiment of FIG. 2 the first grid comprises blank filler panels 42 composed of a conventional tile or fiberboard material, HEPA filter modules 44 comprising a conventional HEPA filter, and light modules 46 which are spaced from the translucent membrane diffusion panel 10 to avoid interference with air flow.
Air flow in the embodiment of FIG. 2 follows a path from workspace 56 to return unit 24 (note the arrows in FIGS. 2 and 3 indicating direction of air flow). The dirty air then passes into duct 26, through optional filter 8 if provided, to fan 30. Fan 30 increases flow pressure, pushing the air into the supply duct. The air then diffuses through the HEPA filters 44 into space 60. Air passes through HEPA Filter modules 44 and is filtered thereby. Clean air then passes into space 60 between the first and second grids. Resistance to air flow through lower grid 36 is provided by controlling the porosity of the various membrane diffusion panels 10. In this manner the system is designed to provide uniform air flow into clean space 56.
FIG. 3 represents an alternate embodiment wherein the HEPA filter 48 is located at the outlet of duct 50. Filtered air is blown into plenum 54 and passes through panels 52 of the first grid which may be composed of any conventional panel material which provides air ventilation. In the embodiment of FIG. 3 a single filter may be used. Ease of replacement of the filter and simplicity in ceiling construction are achieved. Membrane diffusion panels 10 operate in the embodiment of FIG. 3 in the same manner as described above. A vertical flow clean room having ceiling HEPA filters generally requires a uniform flow of approximately 100 feet per minute across the ceiling supply so that the HEPA filters are loaded at the rate of approximately 100 feet per minute face velocity. This low face velocity has the advantage of enabling long filter use without change. New filter technology allows HEPA filters (and bag filters with efficiencies equal to HEPA filters) to be operated at face velocities of 500 feet per minute or higher. The fan filter of FIG. 3 takes advantage of this new technology by loading filter 48 to handle as much air as five conventional ceiling HEPA filters of the same face area. Fan filter unit 48 provides a supply of class 100 air or better into plenum 54. Plenum 54 may be constructed from conventional building materials, for example: Sheetrock, which is taped, floated and painted with an epoxy paint.
Thus it is evident that the present invention realizes improved distribution of air flow without turbulence thereby providing a cost efficient air filtration and distribution system. Although a preferred embodiment of the invention has been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims. | An air filtering and distribution system includes a first planar section, hung from the ceiling of an enclosure, which includes air filter modules, light modules, and blank filler panels. A second planar section spaced from and hung below and generally parallel to the first planar section houses a plurality of membrane diffusion panels for uniformly distributing air through an enclosure without turbulence. The membrane diffusion panels are composed of a fibrous filter panel mounted on a grid shaped ceiling panel. | 5 |
FIELD OF THE INVENTION
The invention relates to asynchronous application programming interfaces (APIs) and more particularly to the return of objects from a call to such an API.
BACKGROUND OF THE INVENTION
As will be familiar to those skilled in the art of programming, a program often comprises function calls which provide a return value(s) for subsequent use in the program. A synchronous program will typically wait for a function to return any values before continuing with its processing. Certain environments however cannot afford such waiting—they require almost instantaneous results. In for example a gaming environment, users are typically not prepared to wait 5 seconds whilst a screen updates. Good performance is required and yet games applications typically use a non-threaded model of programming thus preventing the use of parallel processing to achieve required performance levels. (This is because threads are typically under the control of the operating system and so do not therefore permit tight enough control by the games application programmer.)
To help achieve acceptable performance levels, asynchronous APIs and handles are often used. A handle is an abstract reference (label) which is associated with a function's return value and which can then be used to access that return value.
For example, a user program (application) may call function y on some API which may need to return value r. The time taken to process the request and actually return the value r may however be too long, and will have too large an impact on the user program. Instead, when the function is called, it returns a handle “handle_r”, which is an abstract reference to the actual return value, r, which will initially be unavailable. The work of actually processing the request made as a result of that function, and thus retrieving r, will not be immediately carried out. Instead, the user program will later provide the API with x milliseconds in which to actually do that work, and to obtain the return value r. Once the API's allotted time slot has expired, the user program will then query handle_r to determine whether it resolves to the return value r. If the answer is no, then the user application may do some additional processing, such as redrawing a screen, before requesting that the API re-attempt to obtain r and also before handle_r is queried again. The user application can periodically query the handle (interspersing this with additional processing) until handle_r finally resolves to the result r. Note, when r is finally returned from function y, it is stored in a block of memory and an entry in a lookup table is then resolved such that “handle_r” references the block of memory containing r. This time, when the user program queries handle_r, it is presented with access to r. Because the user application only provides the API with a short period of time in which to retrieve the object, the delay whilst this is happening is not discernible to a user.
In reality (given a good network connection) the return of a single value (simple object) should be achieved within the x milliseconds allowed for. Sometimes however API calls return more complex data structures. For example, a call may return a linked list of items, or a tree of items. Complex data structures are composed of many individual objects. These objects are then linked to each other via the use of object pointers, and the complex data structure is created as a result of this linkage.
When using asynchronous APIs, a function is not able to immediately return a result. Rather, a handle is returned instead. This handle is associated with an eventual return value (i.e. complex structure) generated by the asynchronous API (this value being the result of the initial function call). The user is informed of the return of this result and the association with the handle via a change in the handle's “state” (e.g. it moves from an “Empty” to a “Complete” state). The user then uses the handle to access the return value. As far as the user is concerned, the handle is not resolvable (i.e. is in the “Empty” state) until the structure is complete. The program need however not be blocked since as before it may provide the API with x milliseconds to retrieve n objects. During that time, the API may retrieve only 2 of those objects. These will be associated with a handle but to the user this handle does not yet resolve to a structure because all objects in the structure have not yet been retrieved. The program will continue its processing, will periodically request that the API retrieves more objects and will query the handle to determine whether it is resolvable. This can however take time (especially where network connections are involved and when large structures need to be retrieved) and this can be undesirable.
SUMMARY OF THE INVENTION
According to a first aspect the invention provides a method for facilitating access by an application to a data structure comprising a plurality of objects, the method comprising the steps of: receiving a request from the application initiating the return of the data structure; assigning a handle to each of at least some of the plurality of objects; retrieving objects in the data structure; informing the application of assigned handles thereby enabling the application to access retrieved objects.
Note, no order is intended to be implied by the above. For example, objects could be retrieved and then handles assigned or handles could be assigned and then resolved as and when the associated objects are retrieved.
Note, objects may be retrieved via an intermediary.
Previously a requesting application had to wait for the entire data structure (and the objects it contained) to be returned before objects in the data structure could be accessed. With the present solution it is now possible to provide access to individual objects in a data structure as and when such objects are retrieved. This enables an application to work with retrieved objects whilst other objects are being retrieved/in an interim before more objects in the data structure are retrieved.
In a preferred embodiment, the request comprises a function call which is operable to return the data structure to the application.
In a preferred embodiment responsive to retrieving an object, the retrieved object is assigned to a memory location and a handle is associated with the memory location containing that object. A lookup table can be used to associate each handle with an object/with a memory location containing an object.
In one embodiment, more than one object may be stored in the same block of memory and consequently one handle may be used to reference any objects stored within a particular memory block (logically the block of memory becomes one object).
In a preferred embodiment a request is received from the application to access a retrieved object. The request preferably uses the handle associated with the retrieved object. Preferably access is then provided to the requested object (even though all objects in the data structure may not have yet been retrieved).
In a preferred embodiment, a request may be received to free up a memory location associated with a retrieved object. The memory location is then freed—for example, the memory location is permitted to be overwritten with new data. This is particularly advantageous in the situation where there is not enough memory available to accommodate the complete data structure. The application may determine that certain of the retrieved objects are not required and may then request that any memory allocated to these objects is freed up. Such freed memory can then be used for other objects in the data structure.
According to a second aspect, the invention provides a method for accessing objects in a data structure comprising: providing a request to an asynchronous application programming interface initiating the return of a data structure; receiving notification of a handle assigned to an object in the data structure; and using the notified handle to access the corresponding object.
Note, the same handle may be assigned to more than one object—see above.
Preferably, it is necessary to periodically query the handle to determine whether it is resolvable to a retrieved object.
Preferably the request is a function call which is operable to return the data structure.
Preferably it is possible to access an object in the data structure using an assigned handle. Further, it is preferably possible to use an accessed object to determine the handle assigned to another object in the data structure. For example, a handle to the next object in the data structure (e.g. where the data structure is a linked list) may be stored with the accessed object.
According to a preferred embodiment, it is possible to determine that an accessed object is no longer required. Responsive to determining that the accessed object is no longer required, it is preferably possible to request that memory associated with the accessed object is freed. This is useful since certain objects may not be required by the application (or may only temporarily be required). Memory is frequently at a premium and so it is extremely advantageous to be able to free up memory containing objects that are no longer being accessed.
Note, this is applicable to an implementation which provides for a “non-destructive” read—i.e. where the object remains stored in memory associated with the API, even after it is accessed, and is only destroyed when a function call explicitly freeing up that handle is made.
In another embodiment, destructive reads are provided for—i.e. when a handle is used to retrieve an object for an application, the memory associated with that object is freed, therefore meaning that version of the object that the application now holds is the only one that exists. This also therefore means that that handle cannot be referenced again.
According to a third aspect, the invention provides apparatus for facilitating access by an application to a data structure comprising a plurality of objects, the apparatus comprising: means for receiving a request from the application initiating the return of the data structure; means for assigning a handle to each of at least some of the plurality of objects; means for retrieving objects in the data structure; means for informing the application of assigned handles thereby enabling the application to access retrieved objects.
According to a fourth aspect, the invention provides apparatus for accessing objects in a data structure comprising: means for providing a request to an asynchronous application programming interface initiating the return of a data structure; means for receiving notification of a handle assigned to an object in the data structure; and means for using the notified handle to access the corresponding object.
According to a fifth aspect, the invention provides a computer program comprising program code means adapted to perform the method of the first or second aspect when said program is run on a computer.
According to a sixth aspect, the invention provides a computer program product stored on a computer readable storage medium, the computer program product comprising instructions which, when executed on a data processing host, cause said host to carry out the method of the first or second aspect.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the present invention will now be described, by way of example only, and with reference to the following drawings:
FIG. 1 is a flow chart showing the processing of the present invention in accordance with a preferred embodiment; and
FIG. 2 illustrates a component diagram in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION
The figures shows the processing of the present invention, in accordance with a preferred embodiment, from the perspective of both an application (e.g. a user application) and an asynchronous application programming interface (API). Both figures should be read in conjunction with one another.
A user application 200 calls a function at step 10 (via the function caller component 210 ) which will eventually return a complex structure comprising a plurality of objects. For example the user application may be commerce-based, and will thus enable a user to move around a virtual store and query a catalogue of items stocked by the store. The structure returned by a function may, for example, be a subset of items within the catalogue (a linked list in this case, although the invention is not limited to such).
When the API 260 receives the function call, it determines that the function returns a complex structure and assigns a handle at step 100 (handle assignor 270 ) to the first item in the structure. The API adds the handle into a lookup table (step 110 —lookup component 280 ). The handle resolves to nothing at this point. This handle is then returned to (step 120 —handle returner 235 ) and received by the user application (step 20 —handle receiver 230 ).
The user application does some work (processing—step 30 —processor 240 ) such as drawing the virtual store. It then calls an execute function at step 40 (function caller — 210 ) and allocates x milliseconds to the API for performing this execute function (shown by the dotted arrow). The execute function is performed by the API (step 130 ) and enables the API to carry out any pending work. (Note, the dotted line indicates that steps 120 and 130 are not directly linked.)
When the execute function is called by the user application, the API attempts to retrieve the first item in the list (step 140 —item retriever 290 ). Note, this can take some time, especially if network connections etc. are involved.
When an item is retrieved, it is assigned to a memory location (step 150 —memory assignor 300 ). This memory location is then associated with the handle such that the handle now resolves (step 160 ).
Some other information, which is not exposed to the user application, is used by the API to determine whether there is another item in the list (step 170 ). For example, the API may retrieve information by which it is informed that this is item 20 of 25. The API then manipulates the data retrieved into a form which the user application can understand. E.g.:
item {
string name;
int cost;
handle next;
}
If there is another item, then a handle is also assigned to the “next” field of the retrieved item (step 180 —handle assignor 270 ). Thus a handle is stored in memory with this item (step 190 handle assignor 270 ). (Note, if there isn't another item, then the next field may be assigned a null value or alternatively there may not be such a field.) The handle is also added into the lookup table.
Note, one embodiment handles may be stored separately but this is preferably only applicable to a linked list embodiment where traversing the list in order is not important.
The execute function continues until the allotted time period expires (step 195 )—control is then returned to the user application at step 50 . More than one item may be retrieved during the allotted time period.
Further note, the time period is chosen so that the wait caused to the user application, whilst the API is executing, is not discernible to the user.
When control is returned by the API to the user application, the user application queries the returned handle to determine whether the handle resolves to an object (steps 50 , 6—handle querier 220 ). If the API has managed to retrieve the associated object, the user application will receive an indication that the handle now resolves—not shown in the figure. The user application will then use the assigned handle to access and extract the retrieved item (step 80 —item extractor 250 ). Note, this may involve accessing the object remotely or actually retrieving the object and storing it locally.
As previously mentioned, there may be more items in the list. The user application is able to determine the handle to the next item because it is stored with the item that has just been received. This handle is then preferably used to immediately query whether the new handle resolves (i.e. whether the item associated with the handle has yet been retrieved and assigned to a memory location). This is because the execute function may have managed to retrieve more than one item in the x milliseconds allotted to it.
If the answer is yes, then the handle is used to access this next item and same process continues until it is determined that a handle does not resolve.
Otherwise the user application does some more work before it once again calls the execute function (step 30 —function caller 210 ).
In this way, it is possible to gain access to the individual items (objects) in a complex structure. It is no longer necessary to wait for the entire structure to be returned before permitting the user access to the items (objects) within the structure. Rather the user can now see and work with items as and when they are returned by the API. This is advantageous in multiple respects. Allowing a user to work with certain items whilst others are being returned saves time. Further it is useful in situations where it is not possible to allocate enough memory to an entire structure. Memory can be allocated to objects, consumed by a user application and then destroyed when no longer required. Destruction frees up memory for the rest of the structure. For example, the user may not be interested in “shoes” and is thus able to overwrite memory allocated to any returned items which relate to such items.
Note, handles do not have to be queried immediately control is returned to the user application. Further objects which resolve to queried handles do not have to be retrieved immediately.
It will be appreciated that whilst the invention has been described in terms of a data structure comprising a linked list, the invention is not limited to such. For example, the data structure may comprise a tree of nodes. To use a binary tree as an example, the root object in the tree would be the first item that would be returned from the API. Each of the two child objects of that root object (since this is a binary tree) would then have handles associated with them.
Regarding which of the child objects is returned first, this would partly depend on the API and partly on the source that the object is being retrieved from (e.g. from a commerce service, across the network—certain objects may be retrieved quicker than others because of a better network connection etc.). The API would have to build up its own internal representation of the tree and correctly link all those handles, as and when they're returned. The user of the API would then traverse the tree by just accessing each child (and therefore traversing each branch of the tree) as and when the handles for those child resolve into a state that indicates that the object is now available to be retrieved.
The preferred embodiment assumes that when an object is retrieved, it is retrieved in its entirety. This object retrieval can be subdivided into two steps: receipt of the data that represents the object and parsing of that data to provide the actual object. In some embodiments the parsing of the data can be very expensive. Those embodiments can be further improved by avoiding the parsing step for those objects which the requesting user application does not access. This is achieved by delaying the parsing step until the requesting user application actually accesses the handle associated with the requested object. | There is disclosed a method, apparatus, computer program and computer program product for facilitating access by an application to a data structure comprising a plurality of objects. A request is received from the application which initiates the return of the data structure. A handle is assigned to each of at least some of the plurality of objects. Objects in the data structure are retrieved and the application is informed of assigned handles thereby enabling the application to access retrieved objects. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a wire bonding method for making connection between a die electrode pad and an external lead and more particularly to a method for forming low wire loop during wire bonding.
In wire bonding, when, in order to bond a wire at a second bonding point, a capillary is moved to slightly above the second bonding point, excess wire hangs down from the lower end of the capillary, and a wire shape develops in which a hanging down part is formed. This hanging down part causes a repulsion to occur, when the wire is bonded at the second bonding point, so as to swell upward, resulting in that the straightness of the wire loop deteriorates. Japanese Patent Application Laid-Open Disclosure Nos. (1992) 4-370941 (Japanese Patent No. 3049515) and 2000-82717 disclose wire bonding methods for preventing wire loop from swelling at the time that bonding is made to the second bonding point.
In the method of Japanese Patent Application Laid-Open Disclosure (1992) No. 4-370941 (Japanese Patent No. 3049515), after connecting a wire to a first bonding point, the capillary is positioned slightly above the second bonding point and slightly on the first bonding point side, and then the capillary is descended diagonally in the direction of the second bonding point, thus bonding the wire at the second bonding point. In other words, in the method of Japanese Patent Application Laid-Open Disclosure (1992) No. 4-370941, by way of causing the capillary to descend diagonally, the hanging down part that hangs down from the lower end of the capillary is absorbed.
In the method disclosed in Japanese Patent Application Laid-Open Disclosure (2000) No. 2000-82717, after the wire is connected to a first bonding point, the capillary is lowered slightly from a second bonding point to the first bonding point side so that the capillary presses the hanging down part hanging down from the lower end of the capillary against a horizontal surface, then the capillary is moved to above the second bonding point and then is caused to descend, thus bonding the wire at the second bonding point. In other words, in the method of Japanese Patent Application Laid-Open Disclosure (2000) No. 2000-82717, the wire hanging down from the lower end of the capillary is pressed against a horizontal surface prior to bonding at the second bonding point; as a result, swelling of the wire loop at the time of bonding to the second bonding point is prevented.
Though not directly related to the problems the present invention would resolve, Japanese Patent Application Laid-Open Disclosure (1997) No. 9-51011 hereinafter “JP'51011,” the disclosure of which is herein incorporated by reference, discloses a wire bonding method in which the height of the wire loop from the first bonding point is formed low, of this specification. In this method, in other words, a ball is formed at the tip end of the wire, and this ball is pressure-bonded to a die electrode pad to form a pressure-bonded ball, and then, after performing loop control for moving the capillary to ascend or moving it horizontally, or the like, the wire is pressure-bonded on the pressure-bonded ball to form a wire bonding part. According to JP'51011, by way of performing bonding to the first bonding point, the wire loop height from the first bonding point can be low. For more information on low height loop at the first bonding point, see JP'51011 which is incorporated herein by reference
Even if the capillary is caused to descend diagonally prior to bonding to a second bonding point as disclosed in Japanese Patent Application Laid-Open Disclosure (1992) No. 4-370941 (Japanese Patent No. 3049515), the hanging down part of the wire at the lower end of the capillary, though it is less than that in the conventional method of bonding to a second bonding point, still remains nevertheless. Accordingly, the repulsion caused by plastic deformation of the hanging down part in the wire at the time of bonding at the second bonding point is not avoidable, and swelling occurs in the slanted part of the wire loop.
When the hanging down part is pressed against a horizontal surface, as in the method disclosed in Japanese Patent Application Laid-Open Disclosure (2000) No. 2000-82717, such a banging down part disperses in the interior of the capillary and in the slanted part of the wire loop, causing those respective portions to get loosened. When the capillary ascends to a certain height in the next step, the wire that was loose inside the capillary will be pushed back downward and come out at the lower end of the capillary. Since the wire that came out at the lower end of the capillary at the next bonding to the second bonding point is pressed against the second bonding point, similar to Japanese Patent Application Laid-Open Disclosure (1992) No. 4-370941 repulsion caused by plastic deformation in the wire occurs, and swelling does occur in the slanted part of the wire loop though the amount thereof is smaller than with the conventional method of bonding to the second bonding point.
SUMMARY OF THE INVENTION
Accordingly, the object of the present invention is to provide a wire bonding method in which wire loop is prevented from swelling, thus improving the wire loop straightness.
The above object is accomplished by a set of unique steps of the present invention for a wire bonding method for connecting a wire, which passes through a capillary, between an electrode pad that is a first bonding point and an external lead that is a second bonding point with a use of the capillary; and in the present invention,
after finishing bonding to the electrode pad (first bonding point), the capillary is, together with a clamper, moved to above the external lead (second bonding point); then the capillary (and the clamper) is, with the clamper opened, caused to descend from above the external lead, so that the wire is pressed to such extent as that the wire is not completely connected to the external lead, thus forming a thin part in the wire; next the clamper is closed, and the capillary (and the closed clamper) is caused to ascend, together with the thin part, to substantially the same height as the first bonding point; the capillary (and the clamper) is next moved in a direction away from (or opposite from) the first bonding point, thus pulling the wire bonded to the first bonding point, so that the pulled wire is made into a linear wire portion, and in conjunction therewith, is cut (separated) at the thin part; then the capillary (and the clamper) is moved back in the direction toward the first bonding point and then caused to descend so that the end of the linear wire portion, or the thin part at the end of the linear wire portion, is pressed by the capillary and bonded to the external lead (second bonding point) and, in conjunction therewith, the wire tip end at the lower end of the capillary is bonded also to the external lead; and further, the clamper is opened, and the capillary (and the clamper) is caused to ascend; and during this ascending motion of the capillary, the clamper is closed so that the wire tip end at the lower end of the capillary peeled away (separated) from the external lead, thus forming a tail portion on the wire extending out of the lower end of the capillary, such a tail portion to be used for the next first bonding.
The above object is accomplished by another set of unique steps of the present invention for a wire bonding method for connecting a wire, which passes through a capillary, between an electrode pad that is a first bonding point and an external lead that is a second bonding point with a use of the capillary; and in the present invention,
after finishing bonding to the electrode pad (first bonding point), the capillary is, together with a clamper, moved to above the external lead (second bonding point); then the capillary (and the clamper) is, with the clamper opened, caused to descend from above the external lead, so that the wire is pressed to such extent as that the wire is not completely connected to the external lead, thus forming a thin part in the wire; next the clamper is closed, and the capillary (and the closed clamper) is caused to ascend, together with the thin part, to substantially the same height as the first bonding point; the capillary (and the clamper) is next moved in a direction away from (or opposite from) the first bonding point, thus pulling the wire bonded to the first bonding point, so that the pulled wire is made into a linear wire portion, and in conjunction therewith, is cut (separated) at the thin part; next, the capillary (and the clamper) is caused to descend, and the wire tip end at the lower end of the capillary is bonded to the external lead; then, the clamper is opened, and the capillary (and the clamper) is caused to ascend; and during this ascending motion of the capillary, the clamper is closed so that the wire tip end at the lower end of the capillary peeled away (separated) from the external lead, thus forming a tail portion on the wire extending out of the lower end of the capillary; after forming a ball in this tail portion, the clamper is opened, and the capillary (and the clamper) is moved back in the direction toward the first bonding point and then caused to descend so that the ball is pressed against the end of the above-described linear wire portion, and the ball, together with the end of the linear wire portion, is bonded to the external lead, thus forming a pressure-bonded ball; and then the capillary (and the clamper) is caused to ascend, and during this ascending motion of the capillary, the clamper is closed, so that the wire is cut from the pressure-bonded ball, thus forming a tail portion extending out of the lower end of the capillary, such a tail portion to be used for the next first bonding.
As seen from the above, in the present invention, the capillary is, after the bonding at the first bonding point, moved in a direction away from the first bonding point, thus pulling the wire connected to the first bonding point and making it a linear wire portion, and then this linear wire portion is cut (separated) from the wire at the thin part. Thus, with this step, a spring-up part is formed in the wire bonded to the first bonding point and is then pulled and cut at the thin part to make a one-side supported linear wire portion, and the end of this one-side supported linear wire portion is pressed by the capillary and bonded to the external lead, wherefore wire loop straightness is enhanced.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIGS. 1( a ) through 1 ( c ) show the steps of the wire bonding method according to the first embodiment of the present invention;
FIGS. 2( a ) through 2 ( c ) show the steps continuing from FIG. 1( c );
FIGS. 3( a ) and 3 ( b ) show the steps continuing from FIG. 2( c );
FIGS. 4( a ) through 4 ( c ) show the steps of the wire bonding method according to the second embodiment of the present invention;
FIGS. 5( a ) through 5 ( c ) show the steps continuing from FIG. 4( c ); and
FIGS. 6( a ) and 6 ( b ) show the steps continuing from FIG. 5( c ).
DETAILED DESCRIPTION OF THE INVENTION
A first embodiment of the wire bonding method of the present invention will be described with reference to FIGS. 1( a ) through 3 ( b ).
On a lead frame 2 on which an external lead 1 is formed, a die 4 having thereon an electrode pad 3 is formed is mounted. As seen from FIG. 3( b ), a wire 10 passes through a capillary 5 . The reference numeral 6 indicates a clamper which makes the same horizontal and vertical motions as the capillary 5 whenever the capillary 5 is moved horizontally and vertically.
First of all, bonding is performed at the first bonding point A (first bonding) shown in FIG. 1( a ), thus forming a pressure-bonded ball 11 and, on the pressure-bonded ball 11 , a wire bonding part 12 . The forming of this pressure-bonded ball 11 and wire bonding part 12 is effected by the method of, for instance, Japanese Patent Application Laid-Open Disclosure (1997) No. 9-51011. For more information on low height loop at the first bonding point, see JF'51011 which is incorporated herein by reference.
In other words, as seen from FIG. 3( b ), with the clamper 6 closed, a ball 14 is formed in the tail piece 13 of the wire extending out of the lower end of the capillary 5 , by a spark discharge made by an electric torch (not shown in the drawings).
Next, the clamper 6 attains its open condition, the capillary 5 (and the clamper 6 ) descends after moving above the first bonding point A, and the ball 14 is bonded to the first bonding point A, and then, as seen from FIG. 1( a ), the pressure-bonded ball 11 is formed.
Then, after performing loop control for moving the capillary 5 (and the clamper 6 ) so as to ascend or moving it horizontally, or the like, the wire 10 is pressure-bonded on the pressure-bonded ball 11 to form the wire bonding part 12 .
After that, the capillary 5 (and the clamper 6 ) is moved so that the capillary 5 is positioned slightly above the second bonding point B of the external lead 1 . In this case, a hanging down part 15 of the wire resulting from the excess wire 10 hanging down from the lower end of the capillary 5 is formed.
Next, as shown in FIG. 1( b ), the capillary 5 (and the clamper 6 ) is caused to descend, the wire 10 is pressed against the external lead 1 of the lead frame 2 , and as a result a thin part 16 is formed in the wire. When the wire 10 is pressed against the external lead 1 , the hanging down part 15 of the wire springs up, forming a spring-up part 17 ; and in this case, the thin part 16 of the wire is not completely connected to the external lead 1 ; in other words, a part of the wire is pressed (crushed) by the capillary to make the thin part 16 so that the thin part 16 is raised together with the capillary when the clamper 6 closes and the capillary 5 ascends (with the clamper 6 ) in the next step shown in FIG. 1( c ).
Next, the clamper 6 closes and, as shown in FIG. 1( c ), the capillary 5 is caused to ascend to substantially the same height as the first bonding point A.
Then, as shown in FIG. 2( a ), the capillary 5 (and the clamper 6 ) is moved horizontally in a direction away from (or opposite from) the first bonding point A with the clamper closed. With this horizontal motion of the capillary 5 (and the clamper 6 ), the spring-up part 17 is pulled, and a substantially linear wire portion 18 is formed in the wire that is bonded to the first bonding point, and, in conjunction therewith, the linear wire portion 18 is cut at the thin part 16 .
Next, as shown in FIG. 2( b ), the capillary 5 (and the clamper 6 ) is moved back in a direction toward the first bonding point A so that the lower end of the capillary 5 is positioned above the end 19 of the linear wire portion 18 that has the thin part.
In the next step (second bonding) shown in FIG. 2( c ), the capillary 5 (and the clamper 6 ) is caused to descend, and the end 19 of the linear wire portion 18 is bonded to the external lead 1 or at the second bonding point B. At this time, the wire tip end part 20 extending slightly from the lower end of the capillary 5 is connected also to the external lead 1 .
Then, the clamper 6 opens as shown in FIG. 2( c ); and, as shown in FIGS. 3( a ) and 3 ( b ), the capillary 5 (and the clamper 6 ) is ascended. During this ascending motion of the capillary 5 (and the clamper 6 ), that is, when the capillary 5 (and the clamper 6 ) is ascending in FIG. 3( a ), the clamper 6 closes as shown by arrows in FIG. 3( a ). As a result, as shown in FIG. 3( b ), the wire is pulled upward by the clamper, and the wire tip end part 20 is peeled away (separated) from the external lead 1 , and as a result, a tail piece 13 is formed in the wire at the lower end of the capillary 5 . After a ball 14 is formed in this tail piece 13 by an electric torch (not shown), the bonding process shifts to the step shown in FIG. 1( a ).
As seen from the above, in the steps shown in FIG. 1( c ) to FIG. 2( a ), the spring-up part 17 is pulled and is cut at the thin part 16 , thus forming a one-side supported linear wire portion 18 . The end 19 of this one-side supported linear wire portion 18 is, as seen from FIGS. 2( b ) and 2 ( c ), pressed by the capillary 5 and bonded to the second bonding point B; accordingly, wire loop straightness is enhanced.
A second embodiment of the wire bonding method of the present invention will be described with reference to FIGS. 4( a ) to 6 ( b ). The second embodiment takes the same steps as in the above-described first embodiment shown in FIG. 1( a ) to FIG. 2( a ). FIG. 4( a ) corresponds to the step shown in FIG. 2( a ).
In the above-described first embodiment, after the step shown in FIG. 2( a ), the end 19 of the linear wire portion 18 is bonded directly to the second bonding point B by the capillary 5 . In this second embodiment, after the step of FIG. 4( a ) ( FIG. 2( a )), the end 19 of the linear wire portion 18 is not bonded directly to the second bonding point B by the capillary 5 .
After the step shown in FIG. 4( a ) (or the steps in FIGS. 1( a ) through 2 ( a )), the capillary 5 (and the clamper 6 ) is, as shown in FIG. 4( b ), caused to descend, and the wire tip end part 20 is lightly connected (prebonded) to the external lead 1 .
Then, the clamper 6 next opens as shown in FIG. 4( b ); and, as seen from FIGS. 4( c ) and 5 ( a ), the capillary 5 (and the clamper 6 ) is caused to ascend. During this ascending motion of the capillary 5 (and the clamper 6 ), that is, when the capillary 5 (and the clamper 6 ) is ascending in FIG. 4( c ), the clamper 6 closes. As a result, as shown in FIG. 5( a ), the wire tip end part 20 is peeled away (separated) from the external lead 1 , and a tail portion 25 is formed in the wire in the lower end of the capillary 5 . In this tail portion 25 , a ball 26 is next formed by a spark discharge made by an electric torch (not shown).
Next, with the clamper 6 attaining its open condition, and the capillary 5 (and the clamper 6 ) is moved back in the direction toward the first bonding point A and to above the end 19 of the linear wire portion 18 .
Then, as shown in the step (second bonding) of FIG. 5( c ), the capillary 5 (and the clamper 6 ) is descended, thus pressing the end 19 of the linear wire portion 18 against the external lead 1 , and, in conjunction therewith, bonding the ball 26 on the end 19 of the linear wire portion 18 to the external lead 1 , thus forming a pressure-bonded ball 27 .
Next, as shown in FIGS. 6( a ) and 6 ( b ), the capillary 5 (and the clamper 6 ) is caused to ascend. During the ascending motion of the capillary 5 (and the clamper 6 ), that is, when the capillary 5 (and the clamper 6 ) is ascending in FIG. 6( a ), the clamper 6 closes; as a result, as seen from FIG. 6( b ), the wire 10 is cut from the upper end of the pressure-bonded ball 27 , and the tail piece 13 is formed in the wire at the lower end of the capillary 5 . After forming a ball 14 in the tail piece 13 by a spark discharge made by an electric torch (not shown), the bonding process shifts to the step shown in FIG. 1( a ).
In this second embodiment of the present invention as well, since the end 19 of the one-side supported linear wire portion 18 is bonded to the second bonding point B, wire loop straightness is enhanced as in the above-described first embodiment. In this second embodiment, moreover, since the pressure-bonded ball 27 is formed in the end 19 bonded to the second bonding point B, the thickness of the bonding to the second bonding point B is thick (or thicker than in the first embodiment), and the strength at the second bonding point B is enhanced.
In the embodiments described above, the bonding to the first bonding point A is performed in accordance with the method disclosed in JP'51011 which is incorporated herein by reference; however, the present invention is not limited to use this method, and any ordinary bonding method can be used in the present invention. However, with the bonding method of JP'51011 which is incorporated herein by reference, it is possible to keep the rise from the first bonding point A low, which is preferable. | A wire bonding method including the steps of: descending a capillary 5 from above an external lead 1 to press a wire 10 to such an extent that the wire is not completely connected to the external lead 1 , thus forming a thin part 16 in the wire; next ascending the capillary 5 and the thin part 16 to substantially the same height as a first bonding point A, then moving the capillary 5 in a direction away from the first bonding point A, thus making a linear wire portion 18 and then cutting the wire at the thin part 16 ; then connecting the end 19 (thin part) of the linear wire portion 18 and the wire tip end 20 at the lower end of the capillary 5 are connected to the external lead 1 ; and then separating the wire tip end 20 from the external lead 1. | 8 |
BACKGROUND OF THE INVENTION
[0001] The use of steam or explosive decompression to disintegrate or fiberize wood fibers is well known in the art. However, due to the oxidation of wood and acid hydrolysis, steam explosion processes often result in a loss of brightness, strength and yield. Therefore, there is a need for improving the steam explosion process by minimizing one or more of these detrimental effects.
SUMMARY OF THE INVENTION
[0002] It has now been discovered that a steam explosion process can be improved by combining certain chemicals with the steam such that the high temperatures associated with the steam explosion process accelerate certain desired chemical reactions. In addition, the process of this invention is applied to individual fibers, rather than paper or wood particles, which substantially improves the effectiveness of the treatment. These individual fibers can be virgin pulp fibers or deinked fibers. The resulting modified fibers are able to form handsheets with higher bulk, less brightness reduction, less or no tensile reduction and a higher porosity.
[0003] More specifically, for example, the loss of brightness associated with conventional steam explosion processes can be improved by the addition, prior to steam explosion process, of: peroxide and caustic soda (NaOH); boric acid; free sugars and alditols such as glucitol, maltose, and maltitol; antioxidants such as ascorbic acid and 1-thioglycerol; and/or nitrogen-free complexing agents such as tartaric acid and gluconolactone.
[0004] Strength degradation can be reduced by adding monochloroacetic acid and caustic soda (NaOH) to the individual fibers prior to subjecting them to steam explosion. In addition, other chemicals can be used which contain a fiber reactive group and also contain one or more anionic groups to increase the negative charge density on the fiber surface. The fiber reactive groups which are responsible to form a covalent bond to hydroxyl groups on cellulose fiber, include groups such as monohaloalkyl, monohalotriazine, dihalotriazine, trihalopyrimidine, dihalopyridazinone, dihaloquinoxaline, dihalophtalazine, halobenzothiazole, acrylamide, vinylsulfone, beta-sulfatoethylsylfonamide, beta- chloroethylsulfone, and methylol. Suitable anionic groups include, without limitation, sulfonyl, carboxyl or salts thereof. In addition, the polymeric reactive compound (PRC), comprising a monomer with carboxylic acid groups on adjacent carbon atoms that can form cyclic anhydrides in the form of a five-membered ring could be added for strength improvement. A useful commercial compound is BELCLINE®(DP 80 (FMC Corporation), which is a terpolymer of maleic acid, vinyl acetate and ethyl acetate.
[0005] In order to neutralize any acid generated in the steam explosion process of this invention, in addition to NaOH, other alkaline agents can also be applied to the fibers, such as NaHCO 3 , Na 2 CO 3 , Na 3 PO 4 and the like.
[0006] Hence, in one aspect the invention resides in a process for the treatment of cellulosic fibers comprising: (a) treating an aqueous slurry of individual cellulosic fibers containing brightness and/or strength enhancing chemicals with steam at super atmospheric temperature and pressure; and (b) explosively releasing the super atmospheric steam pressure to produce permanently curled fibers.
[0007] In another aspect, the invention resides in a paper sheet or an absorbent article comprising the curled fibers treated by the processes disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
[0008] A wide variety of cellulosic fibers can be employed in the process of the present invention. Illustrative sources of individual cellulosic fibers include, but are not limited to: wood fibers, such as wood pulp fibers; non-woody paper-making fibers from cotton fibers; fibers from straws and grasses, such as rice and esparto; fibers from canes and reeds, such as bagasse; fibers from bamboos; fibers from stalks with bast fibers, such as jute, flax, kenaf, cannabis, linen and ramie; and fibers from leaf fibers, such as abaca and sisal. It is also possible to use mixtures of one or more kinds of cellulosic fibers. Suitably, the individual cellulosic fibers used are from softwood sources such as pines, spruces, and firs, and hardwood sources such as oaks, eucalyptuses, poplars, beeches, and aspens.
[0009] As used herein, the term “fiber” or “fibrous” is meant to refer to a particulate material wherein the length to diameter ratio of such particulate material is 10 or greater.
[0010] It is generally desired that the cellulosic fibers used herein be wettable. As used herein, the term “wettable” is meant to refer to a fiber or material which exhibits a water-in- air contact angle of less than 90°. Suitably, the cellulosic fibers useful in the present invention exhibit a water-in-air contact angle from about 10° to about 50° and more suitably from about 20° to about 30°. Suitably, a wettable fiber refers to a fiber which exhibits a water-in-air contact angle of less than 90°, at a temperature between about 0° C. and about 100° C., and suitably at ambient conditions, such as about 23° C.
[0011] Suitable cellulosic fibers are those which are naturally wettable. However, naturally nonwettable fibers can also be used. It is possible to treat the fiber surfaces by an appropriate method to render them more or less wettable. When surface treated fibers are employed, the surface treatment is desirably nonfugitive; that is, the surface treatment desirably does not wash off the surface of the fiber with the first liquid insult or contact. For the purposes of this application, a surface treatment on a generally nonwettable fiber will be considered to be nonfugitive when a majority of the fibers demonstrate a water in air contact angle of less than 90° for three consecutive contact angle measurements, with drying between each measurement. That is, the same fiber is subjected to three separate contact angle determinations and, if all three of the contact angle determinations indicate a contact angle of water in air of less than 90°, the surface treatment on the fiber will be considered to be nonfugitive. If the surface treatment is fugitive, the surface treatment will tend to wash off of the fiber during the first contact angle measurement, thus exposing the nonwettable surface of the underlying fiber, and will demonstrate subsequent contact angle measurements greater than 90°. Suitable wettability agents include polyalkylene glycols, such as polyethylene glycols. The wettability agent is used in an amount less than about 5 weight percent, suitably less than about 3 weight percent, and more suitably less than about 2 weight percent, of the total weight of the fiber, material, or absorbent structure being treated.
[0012] It is desired that the cellulosic fibers be used in a form wherein the cellulosic fibers have already been refined into a pulp. As such, the cellulosic fibers will be substantially in the form of individual cellulosic fibers although such individual cellulosic fibers may be in an aggregate form such as a pulp sheet. The current process, then, is in contrast to known steam explosion processes that generally treat cellulosic fibers that are typically in the form of virgin wood chips or the like. Thus, the current process is a post-pulping, or post deinking, cellulosic fiber modifying process as compared to known steam explosion processes that are generally used for high-yield pulp manufacturing or waste-recycle processes.
[0013] The cellulosic fibers used in the steam explosion process of this invention are desirably low yield cellulosic fibers. As used herein, “low yield” cellulosic fibers are those cellulosic fibers produced by pulping processes providing a yield of 85 percent or less, suitably about 80 percent or less, and more suitably about 55 percent or less. In contrast, “high yield” cellulosic fibers are those cellulosic fibers produced by pulping processes providing a yield greater than 85 percent. Such pulping processes generally leave the resulting cellulosic fibers with high levels of lignin.
[0014] In general, the cellulosic fibers may be treated with chemicals in either a dry or a wet state. However, it may be desirable to first prepare an aqueous mixture or slurry of the cellulosic fibers wherein the aqueous mixture is agitated, stirred, or blended to effectively disperse the cellulosic fibers throughout the water. Accordingly, it is desired that the aqueous mixture have a consistency of from about 10 to 100 weight percent, suitably from about 25 to about 80 weight percent and more suitably from about 55 to about 75 weight percent cellulosic fibers, based on the total weight percent of the aqueous pulp mixture. (As used herein, “consistency” refers to the concentration of the cellulosic fibers present in an aqueous mixture. As such, the consistency is a weight percent representing the weight amount of the cellulosic fibers present in an aqueous mixture divided by the total weight amount of cellulosic fibers and water present in such mixture, multiplied by 100.)
[0015] A dewatering means can be used to thicken the aqueous mixture to the desirable consistency. Dewatering means that are suitable for use in the present invention include, but are not limited to, typical equipment used to thicken pulp slurry or sludge slurry such as twin wire press, screw press, belt washer or double nip thickener. Such thickening equipment is well known and is described in various pulp and paper journals and textbooks. To dewater the pulp slurry beyond 60 weight percent consistency, thermal drying processes can be used. An example of a direct thennal drying system is a convection dryer, where hot air or flue gases flow over the pulp slurry and purge the water from the pulp slurry. Among the convection drying processes in the paper industry are drum dryers, belt dryers or rack dryers.
[0016] Chemical addition, such as the addition of brightening agents and/or strength agents, is suitably introduced to the concentrated fiber pulp slurry. A mixing means can be used to mix the brightening agent or strength agent as needed prior to feeding the fiber slurry to the steam explosion reactor. Mixing means that are suitable for this purpose include typical equipment used to mix bleaching chemicals with pulp slurries, such as medium consistency or high consistency mixers available from Ingersoll-Rand, Impco, Andriz and Sunds Defibrator. Such mixing equipment is well known and is described in various pulp and paper journals and textbooks.
[0017] The aqueous mixture of fibers and chemicals is then fed to a suitable steam explosion reactor. Such reactors are well known in the art. Suitable equipment and methods for steam explosion may be found, for example, in Canadian Patent No. 1,070,537, dated Jan. 29, 1980; Canadian Patent No. 1,070,646, dated Jan. 29, 1980;
[0018] Canadian Patent No. 1,119,033, dated Mar. 2, 1982; Canadian Patent No. 1,138,708, dated Jan. 4, 1983; and U.S. Pat. No. 5,262,003, issued Nov. 16, 1993, all of which are incorporated herein in their entirety by reference.
[0019] In carrying out the steam explosion process, it is desired that the cellulosic fibers and chemicals are cooked in a saturated steam environment that is substantially free of air. The presence of air in the pressurized cooking environment may result in the oxidation of the cellulosic fibers. As such, it is desired that the cellulosic fibers are cooked in a saturated steam environment that comprises less than about 5 weight percent, suitably less than about 3 weight percent, and more suitably less than about 1 weight percent of air, based on the total weight of the gaseous environment present in the pressurized cooking environment.
[0020] The individual cellulosic fibers are steam cooked at a high temperature and at a high pressure in the presence of the added chemicals. In general, any combination of high pressure, high temperature, and time which is effective in achieving a desired degree of modification, without undesirable damage to the cellulosic fibers, so that the cellulosic fibers exhibit the desired liquid absorbency properties as described herein, is suitable for use in the present invention.
[0021] Generally, if the temperature used is too low, there will not be a substantial and/or effective amount of modification of the cellulosic fibers that occurs. Also, generally, if the temperature used is too high, a substantial degradation of the cellulosic fibers may occur which will negatively affect the properties exhibited by the treated cellulosic fibers. As such, as a general rule, the cellulosic fibers will be treated at a temperature within the range from about 130° C. to about 250° C., suitably from about 150° C. to about 225° C., more suitably from about 160° C. to about 225° C., and most suitably from about 160° C. to about 200° C.
[0022] Generally, the cellulosic fibers and chemicals will be subjected to an elevated superatmospheric pressure over a time period within the range of from about 0.1 minute to about 30 minutes, beneficially from about 0.5 minute to about 20 minutes, and suitably from about 1 minute to about 10 minutes. In general, the higher the temperature employed, the shorter the period of time generally necessary to achieve a desired degree of modification of the cellulosic fibers. As such, it maybe possible to achieve essentially equivalent amounts of modification for different cellulosic fiber samples by using different combinations of high temperatures and times.
[0023] Generally, if the pressure used is too low, there will not be a substantial and/or effective amount of modification of the cellulosic fibers that occurs. Also, generally, if the pressure used is too high, a substantial degradation of the cellulosic fibers may occur which will negatively affect the properties exhibited by the crosslinked cellulosic fibers. As such, as a general rule, the cellulosic fibers will be treated at a pressure that is superatmospheric (i.e. above normal atmospheric pressure), within the range from about 40 to about 405 pounds per square inch, suitably from about 40 to about 230 pounds per square inch, and more suitably from about 90 to about 230 pounds per square inch.
[0024] After steam cooking the cellulosic fibers, the pressure is released and the cellulosic fibers are exploded into a release vessel. The steam explosion process generally causes the cellulosic fibers to become modified. Without intending to be bound hereby, it is believed that the steam explosion process causes the cellulosic fibers to undergo a curling phenomenon. The steam exploded cellulosic fibers, in addition to being modified, have been discovered to exhibit improved properties that make such steam exploded cellulosic fibers suitable for use in liquid absorption or liquid handling applications.
[0025] In one embodiment of the present invention, the cellulosic fibers will be considered to be effectively treated by the steam explosion process when the cellulosic fibers exhibit a Wet Curl Index (hereinafter defined) of about 0.2 or greater, more specifically from about 0.2 to about 0.4, more specifically from about 0.2 to about 0.35, more specifically from about 0.22 to about 0.33, and more specifically from about 0.25 to about 0.33. In contrast, cellulosic fibers that have not been treated generally exhibit a Wet Curl Index that is less than about 0.2.
[0026] After the cellulosic fibers have been effectively steam exploded, the treated cellulosic fibers are suitable for use in a wide variety of applications. However, depending on the use intended for the treated cellulosic fibers, such treated cellulosic fibers may be washed with water. If any additional processing procedures are planned because of the specific use for which the treated cellulosic fibers are intended, other recovery and post- treatment steps are also well known.
[0027] The cellulosic fibers treated according to the process of the present invention are suited for use in disposable absorbent products such as diapers, adult incontinent products, and bed pads; in catamenial devices such as sanitary napkins, and tampons; other absorbent products such as wipes, bibs, wound dressings, and surgical capes or drapes; and tissue-based products such as facial or bathroom tissues, household towels, wipes and related products.
Test Procedures
[0028] Wet Curl Index
[0029] The curl of a fiber may be quantified by a measuring the fractional shortening of a fiber due to kink, twists, and/or bends in the fiber. For the purposes of this invention, a fiber's curl value is measured in terms of a two dimensional plane, determined by viewing the fiber in a two dimensional plane. To determine the curl value of a fiber, the projected length of a fiber, “L 1 ”, which is the longest dimension of a two-dimensional rectangle encompassing the fiber, and the actual length of the fiber, “L”, are both measured. An image analysis method may be used to measure L and L 1 . A suitable image analysis method is described in U.S. Pat. No. 4,898,642, incorporated herein by reference in its entirety. The curl value of a fiber can then be calculated from the following equation:
curl value=( L/L 1 )−L 1 .
[0030] Depending on the nature of the curl of a cellulosic fiber, the curl may be stable when the cellulosic fiber is dry but may be unstable when the cellulosic fiber is wet. The cellulosic fibers prepared according to the process of the present invention have been found to exhibit a substantially stable fiber curl when wet. This property of the cellulosic fibers may be quantified by a Wet Curl Index value, as measured according to the test method described herein, which is a length-weighted mean average of the curl value for a designated number of fibers, such as about 4000 fibers, from a fiber sample. As such, the Wet Curl Index is the summation of the individual wet curl values for each fiber multiplied by the fiber's actual length, L, and divided by the summation of the actual lengths of the fibers. It is hereby noted that the Wet Curl Index, as determined herein, is calculated by only using the necessary values for those fibers with a length of greater than about 0.4 millimeter.
[0031] The Wet Curl Index for fibers is determined by using an instrument which rapidly, accurately, and automatically determines the quality of fibers, the instrument being available from OpTest Equipment Inc., Hawkesbury, Ontario, Canada, under the designation Fiber Quality Analyzer, OpTest Product Code DA93. Specifically, a sample of dried cellulosic fibers to be measured is poured into a 600 milliliter plastic sample beaker to be used in the Fiber Quality Analyzer. The fiber sample in the beaker is diluted with tap water until the fiber concentration in the beaker is about 10 to about 25 fibers per second for evaluation by the Fiber Quality Analyzer.
[0032] An empty plastic sample beaker is filled with tap water and placed in the Fiber Quality Analyzer test chamber. The <System Check> button of the Fiber Quality Analyzer is then pushed. If the plastic sample beaker filled with tap water is properly placed in the test chamber, the <OK> button of the Fiber Quality Analyzer is then pushed. The Fiber Quality Analyzer then performs a self-test. If a warning is not displayed on the screen after the self-test, the machine is ready to test the fiber sample.
[0033] The plastic sample beaker filled with tap water is removed from the test chamber and replaced with the fiber sample beaker. The <Measure> button of the Fiber Quality Analyzer is then pushed. The <New Measurement> button of the Fiber Quality Analyzer is then pushed. An identification of the fiber sample is then typed into the Fiber Quality Analyzer. The <OK> button of the Fiber Quality Analyzer is then pushed. The <Options> button of the Fiber Quality Analyzer is then pushed. The fiber count is set at 4,000. The parameters of scaling of a graph to be printed out may be set automatically or to desired values. The <Previous> button of the Fiber Quality Analyzer is then pushed. The <Start> button of the Fiber Quality Analyzer is then pushed. If the fiber sample beaker was properly placed in the test chamber, the <OK> button of the Fiber Quality Analyzer is then pushed. The Fiber Quality Analyzer then begins testing and displays the fibers passing through the flow cell. The Fiber Quality Analyzer also displays the fiber frequency passing through the flow cell, which should be about 10 to about 25 fibers per second. If the fiber frequency is outside of this range, the <Stop> button of the Fiber Quality Analyzer should be pushed and the fiber sample should be diluted or have more fibers added to bring the fiber frequency within the desired range. If the fiber frequency is sufficient, the Fiber Quality Analyzer tests the fiber sample until it has reached a count of 4000 fibers, at which time the Fiber Quality Analyzer automatically stops. The <Results> button of the Fiber Quality Analyzer is then pushed. The Fiber Quality Analyzer calculates the Wet Curt value of the fiber sample, which prints out by pushing the <Done> button of the Fiber Quality Analyzer.
[0034] Preparation of Wet-Laid Handsheet
[0035] A) Handsheet Forming:
[0036] A 7½ inch by 7½ inch handsheet has a basis weight of about 60 grams per square meter and was prepared using a Valley Handsheet mold, 8×8 inches. The sheet mold forming wire is a 90×90 mesh, stainless steel wire cloth, with a wire diameter of 0.0055 inches. The backing wire is a 14″×14″ mesh with a wire diameter of 0.021 inches, plain weave bronze. Taking a sufficient quantity of the thoroughly mixed stock to produce a handsheet of about 60 grams per square meter. Clamp the stock container of the sheet mold in position on the wire and allow several inches of water to rise above the wire. Add the measured stock and then fill the mold with water up to a mark of 6 inches above the wire. Insert the perforated mixing plate into the mixture in the mold and slowly move it down and up 7 times. Immediately open the water leg drain valve. When the water and stock mixture drains down to and disappears from the wire, close the drain valve. Raise the cover of the sheet mold. Carefully place a clean, dry blotter on the formed fibers. Place the dry couch roll at the front edge of the blotter. The fibers adhering to the blotter, are couched off the wire by one passage of the couching roll, without pressure, from front to back of wire.
[0037] B) Handsheet Pressing:
[0038] Place the blotter with the fiber mat adhering to it in the hydraulic press, handsheet up, on top of tow used, re-dried blotters. Two new blotters are placed on top of the handsheet. Close the press, clamp it and apply pressure to give a gauge reading that will produce 75 PSI on the area of the blotter affected by the press. Maintain this pressure for exactly one minute. Release the pressure on the press, open the press and remove the handsheet.
[0039] C) Handsheet Drying:
[0040] Place the handsheet on the polished surface of the sheet dryer (Valley Steam hot plate). Carefully lower the canvas cover over the sheet and fasten the 131 b . dead weight to the lead filled brass tube. Allow the sheet to dry for 2 minutes. The surface temperature, with cover removed, should average 100.5 plus or minus 1 degree C. Remove the sheet from the dryer and trim to the 7½ inch×7½ inch. Weigh the sheet immediately.
[0041] Testing of Handsheets
[0042] Handsheets shall all be tested at the standard 50% humidity and 73 degree F temperature basis.
[0043] Bulk
[0044] The Bulk of the handsheets is determined according to TAPPI (Technical Association of Pulp and Paper Industry) test method (T220 om-88).
[0045] Brightness
[0046] The Brightness of the handsheets is determined in accordance with TAPPI test method T525 om-92.
[0047] Tensile Index
[0048] The Tensile Index of the handsheets is determined in accordance with TAPPI (Technical Association of Pulp and Paper Industry) test method (T220 om-88).
[0049] Dry Tensile Strength
[0050] The Dry Tensile Strength is determined by in accordance with TAPPI test method T220 om-88, but reported in the unit of grams/in.
[0051] Wet Tensile Strength
[0052] The Wet Tensile Strength is determined by the same procedures for dry tensile strength test as described above, but with the following modifications:
[0053] 1. Pour distilled water to about {fraction (1/2)}- ¾ inch depth in the container. Maintain this depth when testing numerous specimens.
[0054] 2. When testing handsheets, from an open loop by holding each end of the test strip and carefully lowering the specimen until the lowermost curve of the loop touches the surface of the water without allowing the inner side of the loop to come together.
[0055] 3. Touch the lowermost point of the curve on the handsheet to the surface of the distilled water in such a way that the wetted area on the inside of the loop extends at least 1 inch and not more than 1.5 inches lengthwise on the strip and is uniformed across the width of the strip. Do not wet the strip twice. Do not allow the opposite sides of the loop to touch each other or the sides of the container.
[0056] 4. Remove the excess water from the test specimen by touching the wetted area to a blotter. Blot the specimen only once. Blotting more than once will cause fiber damage and too much moisture to be removed.
[0057] 5. To avoid excess wicking, immediately insert the test specimen into the tensile tester so the jaws are clamped to the dry areas of the strip with the wet area about midway between the jaws. +
EXAMPLES
Example 1
[0058] (Prior Art).
[0059] A dried northern softwood kraft pulp (available from Kimberly-Clark Corporation under the designation LL-19) was made into a slurry and dewatering to form a mixture having a consistency of about 30% weight percent cellulosic fibers with a laboratory centrifuge. The said fibers were dried to 75% consistency using an oven set at 50 degree C. Samples of about 200 grams, based on a dry basis of cellulosic fibers, were added to a laboratory steam explosion reactor, available from Stake Tech., Canada. The reactor had a capacity of 2 liters. After closing the top valve, saturate steam at 200 degree C. was injected into the reactor. The pulp fibers were directly contacted with the steam for 2 minutes. The cellulosic fibers were then explosively decompressed and discharged to a container by opening the bottom valve. The steam-exploded fibers were collected for evaluation.
[0060] The cellulosic fiber samples of steam-explosion treated fibers and untreated control fiber samples were formed into handsheet according to procedure described herein and the formed handsheets were evaluated for Bulk and Tensile Index. The Wet Curl Index of the steam-explosion treated and untreated fibers were also measured. The results of these evaluations are summarized in Table 1.
TABLE 1 Bulk Tensile Index Wet Curl (cm^ 3/gram) (Nm/grams) Brightness Index control 2.39 20.97 88.6 0.11 Steam- 2.73 12.87 84.4 0.22 explosion treated
[0061] This example demonstrates that the conventional steam explosion treatment increases bulk, decreases tensile strength and decreases brightness.
Example 2
[0062] (Invention).
[0063] A wet lap of de-ink fibers (available from Ponderosa Recycle Fiber) was dried to 80% consistency using an oven set at 80 degree C. Samples of about 200 grams, based on a dry basis of cellulosic fibers, were mixed with 0.5% peroxide (H2O2) and 0.2% caustic soda (NaOH) [based on a dry basis of fibers] and resulting a mixture of fibers and chemicals at 50% consistency. The said mixture was added to a laboratory steam explosion reactor, available from Stake Tech., Canada. The reactor had a capacity of 2 liters. After closing the top valve, saturate steam at 200 degree C. was injected into the reactor. The pulp fibers were directly contacted with the steam for 2 minutes. The cellulosic fibers were then explosively decompressed and discharged to a container by opening the bottom valve. The steam-exploded fibers were collected for evaluation.
[0064] Additional samples mixtures having peroxide addition from 1% to 3% and caustic soda addition from 0.4% to 0.8%were prepared.
[0065] The cellulosic fiber samples of steam-explosion treated fibers and untreated control fiber samples were formed into handsheet according to procedure described herein and the formed handsheets were evaluated for Bulk and Tensile Index. The results of these evaluations are summarized in Table 2.
TABLE 2 Steam Steam Steam Steam explosion explosion explosion explosion Steam with with with with control explosion chemicals chemicals chemicals chemicals Peroxide, 0 0 0.5 1 2 3 % Caustic 0 0 0.2 0.4 0.6 0.8 Soda, % Bulk, 2.23 2.47 2.38 2.39 2.37 2.39 (cm^ 3/g) Tensile 32.01 22.72 28.33 23.94 22.79 23.83 Index, (NM/g) Brightness 81.93 72.7 80.35 80.75 80.06 80.47
[0066] This example shows reduced brightness reduction.
Example 3
[0067] (Invention).
[0068] A wet lap of de-ink fibers (available from Ponderosa Recycle Fiber) were mixed with 2% and 4% boric acid, based on a dry basis of fibers, and resulting a mixture of fibers and chemicals at 30% consistency. Samples of about 200 grams, based on a dry basis of cellulosic fibers, Then the said mixture was added to a laboratory steam explosion reactor, available from Stake Tech., Canada. The reactor had a capacity of 2 liters. After closing the top valve, saturate steam at 200 degree C. was injected into the reactor. The pulp fibers were directly contacted with the steam for 4 minutes. The cellulosic fibers were then explosively decompressed and discharged to a container by opening the bottom valve. The steam-exploded fibers were collected for evaluation. The results are summarized in Table 3.
TABLE 3 Code 1 Code 2 Code 3 Code 3 Steam No (as control) yes Yes yes explosion Boric acid, % 0 0 2 4 Brightness, % 84.94 78.49 81.3 81.05
[0069] This example shows improved brightness with the addition of boric acid compared to the steam-exploded sample without boric acid addition.
Example 4
[0070] (Invention).
[0071] A dried northern softwood kraft pulp (available from Kimberly-Clark Corporation under the designation LL-19) was made into a slurry and dewatering to form a mixture having a consistency of about 30% weight percent cellulosic fibers with a laboratory centrifuge. Samples of about 200 grams, based on a dry basis of cellulosic fibers, were mixed with 8.6% monochloroacetic acid sodium salt and 2.2% caustic soda [based on a dry basis of fibers] and resulting a mixture of fibers and chemicals at 20% consistency. The mixture was retained in a container for 2 hours at room temperature. Then the said mixture was added to a laboratory steam explosion reactor, available from Stake Tech., Canada. The reactor had a capacity of 2 liters. After closing the top valve, saturate steam at 160 degree C. was injected into the reactor. The pulp fibers were directly contacted with the steam for 2 minutes. The cellulosic fibers were then explosively decompressed and discharged to a container by opening the bottom valve. The steam-exploded fibers were collected for evaluation. One percent of Kymene (wet strength agent available from Hercules Corp.) based on dry weight of fiber was added to the fiber before handsheets were made. The results are summarized in Table 4.
TABLE 4 Control* Code 1 Code 2 Code 3 Code 4 Code 4 Code 5 NaOH 0 2.2 3 4.4 5.9 6.7 8.9 ClCH2C 0 8.6 8.6 17.2 17.2 25.8 25.8 OONa Bulk 2.25 2.84 2.84 2.88 2.84 2.8 2.8 (cm 3/g) Dry 4754 4716 4488 4772 4732 4870 5028 Tensile strength, (g/in) Wet 1179 1396 1431 1422 1410 1534 1604 Tensile strength, (g/in) Ratio of 24.8 29.6 31.9 29.8 31.2 31.5 31.9 Wet/Dry tensile, %
[0072] This example shows maintenance of strength and increased bulk, as well as an increase in the ratio of the Wet Tensile Strength to the Dry Tensile Strength.
[0073] The foregoing examples, given for purposes of illustration, are not to be construed as limiting the scope of the invention which is defined by the following claims and all equivalents thereto. + | Virgin fibers or de-inked recycled fibers modified by steam explosion in the presence of certain chemicals are able to form handsheets with higher bulk while substantially retaining strength and brightness. | 3 |
BACKGROUND OF THE INVENTION
Prior art devices have been cumbersome, complicated, expensive and required more than one operator in order to effectuate a fine adjustment of the holding device.
BRIEF SUMMARY OF THE INVENTION
This invention comprises a novel and a useful adjustable lift scaffold for building panels and other materials and, more particularly, pertains to a mobile vertically adjustable platform to assist in elevating building panels and other materials into proper position to enable their application to an overhead portion of a building structure by a single operator.
The primary object of this invention is to provide an improved adjustable scaffold-type construction specifically adapted for use in aiding the worker in properly positioning ceiling panels or other building materials in readiness for their attachment to a building structure.
A specific objective of the invention is to provide a frame-like mobile scaffold construction consisting of a mobile base having a vertically telescoping and vertically adjustable carriage slidably mounted thereon which carriage is provided with suitable support surfaces for building panels or other materials which are difficult to handle by only one worker and to facilitate their positioning in different vertical elevations, as high as nine and one-half feet (9 1/2) in readiness for their attachment to a building structure and the like.
A further and more specific object of the invention is to provide an adjustable scaffold in accordance with the preceding objects wherein improved means are provided to facilitate the elevation of the vertically movable carriage with its load thereon in a simple manner and with a minimum of exertion on the part of the worker.
Yet another object of the invention is to provide a device in accordance with the preceding objects wherein the carriage is compactly guided and telescopingly mounted within the frame work of the mobile base of the device whereby the framework of the carriage is not only guided by the framework of the base but serves to rigidify the latter.
A still further specific object of the invention is to provide an adjustable scaffold pursuant to the foregoing objects and having no bottom or side structure to hamper accessibility and freedom of movement of the operator's stepladder therethrough and underneath the under side of panels or other objects supported by the scaffold. Thus assuring a more upright position of the operator's stepladder and a more upright position with less exertion for the operator.
A final specific object of the invention to be enumerated herein is to provide a portable scaffold consisting of a movable base having a vertically adjustable carriage mounted upon said base with no side structure attached thereto, especially at the bottom. Having a mobile base with side structure attached thereto, especially at the bottom, denies proper positioning of the operator's stepladder causing the operator to take a sideways leaning position whereby access through the side structure from underneath the ceiling panels or other building materials supported by the scaffold requires extra exertion on the part of the operator and may cause a slip of the ladder, perhaps, resulting in serious injuries to the operator.
These, together with other objects and advantages which will become subsequently apparent, are provided by the present invention, the details of construction and operation of which are more fully hereinafter described.
DESCRIPTION OF THE DRAWINGS
Reference is made to the accompanying drawings, forming a part hereof, wherein like numerals refer to like parts throughout, and in which:
FIG. 1 is a perspective view of the adjustable building panel scaffold in accordance with this invention;
FIG. 2 is a perspective view of the adjustable building panel scaffold in readiness to be used in smaller rooms such as bathrooms;
FIG. 3 is a fragmentary view of the telescoping and lifting mechanism; and
FIG. 4 is a partially cutaway view of the winch means.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIG. 1, it will be seen that the adjustable panel lifting apparatus 1 includes a base unit 2 and a carriage unit 3. The base unit 2 has a first end unit 4 and a second end unit 5 both of which are of open frame work construction, for example, of galvanized pipe conventionally employed in the construction of scaffolding.
The base unit 2 has first end unit 4 formed by two hollow vertical leg members 6 and hollow central vertical leg 7 connected at their bottom by lower horizontal transverse brace 19 and adjacent the upper ends of said vertical legs 6 and 7 by upper horizontal transverse brace 18 by conventional means such as corner clamps, welding, threaded pipe connectors and the like. Central vertical leg 7 has connected at its lower end and normal to first end unit 4 hollow lower central horizontal longitudinal brace 9 and adjacent the upper end of central vertical leg 7, also normal to the plane of first end unit 4, upper hollow central horizontal longitudinal brace 8, both of which are connected at the distal ends from first end unit 4 by upper and lower central hollow horizontal longitudinal brace connector leg 25.
Similarly, second end unit 5 has two hollow vertical legs 6 and hollow central vertical leg 12 connected by upper and lower horizontal transverse braces 18 and 19, respectively, forming a generally rectangular open framework. Solid upper central horizontal longitudinal brace 10 is connected at one end adjacent the upper end of hollow central vertical leg 12 and has its distal end inserted into the said brace 8. Likewise, solid lower central horizontal longitudinal brace 11 is connected at one end adjacent the lower end of hollow central vertical leg 12 and has its distal end inserted into the said brace 9. Thus, the first end unit 4 and the second end unit 5 are slidably and telescopingly engaged and the length of base unit 2 can be adjustable to fit the panels and rooms in which it is used. Although not depicted in FIG. 1, it can be readily envisioned by the skilled worker that in a similar manner vertical legs 6 can be made slidably adjustable so that base unit 2 can be also made wider or narrower to fit panels or rooms with which the invention may be used.
As further seen in FIG. 1, carriage unit 3 is of generally open framework construction in a rectangular form and located in a plane normal to the vertical. Hollow longitudinal horizontal carriage unit support members 21 are connected at one end by transverse carriage unit horizontal support member 20. At their distal ends said support members 21 have slidably inserted therein solid longitudinal horizontal carriage unit support members 22 which are connected by transverse carriage unit horizontal support member 20. Thus, the said members 20, 21 and 22 form the rectangular open framework upon which a ceiling panel or other building material is rested and held in place before, during and while attaching the panel to the ceiling rafters or other building structure. This composite framework is guided by solid vertical legs 13 at each corner of the carriage unit 3 and end units 4 and 5, respectively, being in slidable and telescoping engagement within hollow vertical legs 6 of base unit 2. The carriage unit is lifted into position by central downwardly extending legs 23 located at substantially the center of transverse horizontal support members 20 and extending in slidable telescoping relation into or out of hollow central vertical legs 7 and 12 of said first and said second end units 4 and 5, respectively. The corners of carriage unit 3 can be connected by any conventional means such as by welding, threaded pipe connections, or by corner brackets 31, as shown in FIG. 1.
The lifting of carriage unit 3 is accomplished by actuating means 14. Actuating means 14 includes double acting winch means 30 located about midway between said first and said second end units 4 and 5 on upper central hollow longitudinal horizontal brace 8, cable slack take up means 26 which also includes adjustable cable slack take up post 27, having at its upper end pulley 29 and being slidably adjustable in bracket 28 which can be tightened by adjusting wing units 40. Winch means 30 has attached thereto cables 17 of substantially equal length which run under lower base unit pulleys 15, located adjacent the connection of brace 8 and central vertical leg 7 in said first end unit 4 and adjacent the connection of brace 10 and central vertical leg 12 in said second end unit 5, and over upper base unit pulleys 16, located, respectively, at the upper ends of central vertical legs 7 and 12, and are attached to carriage unit 3 at the bottom of downwardly extending legs 23. Thus, the actuating means 14 can be used to raise or lower carriage unit 3 by operation of winch means 30 to wrap or unwrap cables 17 which acting over said pulleys 15 and 16 shorten or lenghthen the cable attached to downwardly extending legs 23. Winch means 30 can be any conventional double acting winch equipped with a gearlock, having for easy manual operation and smooth lifting or lowering, a gear ratio of at least 3 to 1. The winch should lock at any height and have a lifting capacity of at least about 700 pounds.
Referring to FIG. 2, it can be easily seen that the portable panel lift apparatus 1 is similar to that of FIG. 1, except that it is longitudinally compressed or adjusted for use and operation in a small room. In such configuration, the cables 17 have unequal distances to travel. To lengthen the path of cable 17 to said second end unit 5 cable slack take-up means 26 is employed. Depending on how much slack is put in cable 17 because of the shortened distance to said second end unit, cable 17 is threaded over pulley 29 and post 27 is adjusted in height by wing nuts 40 in bracket 28 to take out the slack in cable 17, all of this being done while carriage unit 3 is unloaded and in lowered position. Thus, the same length path will always be traveled by cable 17 and the lift on carriage unit 3 will be equal on each end.
In FIG. 3, there is shown, as a specific embodiment, one means of attachment of cable 17 to downwardly extending leg 23 and operation of slidable relation between said downwardly extending leg 23 and central vertical leg 12, for example. As shown, the end 35 of leg 23 has the end of cable 17 welded thereto for greater safety. Although this method is shown, one could also employ hook-and-eye bolts, attachment by knotting cable 17 through a hole in the end 35 or other conventional means. The cable 17 passes through slot 33 in downwardly extending leg 23, over pulley 16, held by pulley bracket 34 and so forth back to winch means 30 as more particularly described in FIG. 1.
Winch means 30 is shown in cutaway detail in FIG. 4 to primarily illustrate the attachment of cable 17 to the drum of winch means 30. Winch means 30 is held to the apparatus 1 by base plate 38 welded or otherwise conventionally attached to upper central hollow horizontal longitudinal brace 8. Baseplate 38 has winch bracket 37 attached thereto and central axis 39 of winch 30 is also located therein. The gears, lock and handle are conventional and well within the skill of the art. Cable 17 is attached to winch drum at points 180° apart so that turning winch 30 balances the opposing weight of the carriage unit 3 and the load.
In order to impart mobility to the structure, the base unit has provided castor wheel units 24. As thus far described, it will be apparent that building panels such as 4 × 8 masonite, plywood, plaster boards, sheetrock and other ceiling panels or other building material may be rested upon the top of the carriage unit 3 and may be manually adjusted by operating double acting winch means 30. Thus, a ceiling panel may be held against a ceiling for attachment thereto by the worker. Further, this adjustable scaffold may be utilized for various other purposes for vertically positioning different building materials of much greater areas or sizes than have been previously mentioned. For this purpose, it was firmly constructed of strong durable, lasting and rustproof galvanized steel pipes. It will be appreciated that a worker can, by virtue of the open top construction of the carriage unit 3 and open construction of the bottom of the base unit 2, obtain access to the underside of any building material, without having to assume a leaning sideways and uncomfortable and dangerous position when it is desired to secure the material against overhead structures.
The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. Accordingly, all suitable modifications and equivalents may be resorted to, falling within the lawful scope of the invention described in the appended claims. | An elevatable and adjustable scaffold device for supporting ceiling or other panels usually attached to overhead rafters and ceiling beams, operable by one person and capable of fine adjustment for height, as well as length and width for working in small rooms. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to Korean Patent Application No. 10-2008-0121487 filed on Dec. 2, 2008, the entire contents of which are incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a variable compression ratio apparatus. More particularly, the present invention relates to a variable compression ratio apparatus that varies the compression ratio of a mixed gas inside a combustion chamber according to driving conditions of an engine.
[0004] 2. Description of Related Art
[0005] A variable compression ratio (VCR) apparatus varies the compression ratio of a mixed gas corresponding to operating conditions of an engine. According to the variable compression ratio apparatus, the compression ratio of the mixed gas is raised to decrease fuel consumption in a low load condition of the engine, and the compression ratio of the mixed gas is lowered to prevent “knocking” and to improve the output thereof in a high load condition of the engine.
[0006] The conventional variable compression ratio apparatus describes a multi-link type of control means that includes a connecting rod, which is connected to a piston to receive the explosion force of the mixed gas, and a pin link, which receives the explosion force from the connecting rod to rotate the crankshaft, to vary the rotation track of the pin link according to the driving condition of the engine such that the compression ratio of the mixed gas can be varied.
[0007] However, in the conventional variable compression ratio apparatus having a multi-link type of control means, a journal portion for mounting the control shaft is formed inside the crankcase of a cylinder block, and so on, so there is a drawback that the structure thereof is complicated.
[0008] The information disclosed in this Background of the Invention section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
BRIEF SUMMARY OF THE INVENTION
[0009] Various aspects of the present invention are directed to provide a variable compression ratio apparatus for varying a compression ratio in which the structure thereof is simple and compact.
[0010] In an aspect of the present invention, the variable compression ratio apparatus for varying a compression ratio, may include a connecting rod that is pivotally connected to a piston to take a combustion force, a pin link, one end of which is eccentrically connected to a crankshaft and the other end of which is pivotally connected to the connecting rod to form a connection portion therebetween, a slot link including a control slot to receive and guide the connection portion along the control slot, and a driving unit coupled to the slot link and configured to move the control slot to control a position of the connection portion.
[0011] The control slot may have an arc shape of a predetermined curvature.
[0012] In another aspect of the present invention, the driving unit may include a hydraulic pressure cylinder to receive an operating rod therein, one side of the slot link being pivotally fixed to the crankcase, a rear end of the hydraulic pressure cylinder being pivotally fixed to the crankcase, and a front end of the operating rod being pivotally connected to the other side of the slot link.
[0013] In another aspect of the present invention, the driving unit may include a motor mounted to the crankshaft, and a pinion being connected to a rotation shaft of the motor, wherein one side of the slot link is pivotally connected to the crankcase and a rack portion is formed in the other side of the slot link such that the pinion is engaged with the rack portion of the slot link.
[0014] In further another aspect of the present invention, the driving unit may include a motor being mounted in the crankcase, an eccentric cam being mounted to a rotation shaft of the motor, and a link, wherein a cam ring, through which the eccentric cam is inserted, is configured on one end of the link and the other end of the link is pivotally connected to one side of the slot link and the other side of the slot link is pivotally connected to the crankcase
[0015] In another aspect of the present invention, the driving unit may include a motor that is mounted in the crankcase and one side of the slot link being fixed to a rotation shaft of the motor.
[0016] In further another aspect of the present invention the driving unit may include a vane type of a hydraulic pressure actuator, and one side of the slot link is fixed to a center shaft of the hydraulic pressure actuator and is provided with hydraulic pressure to rotate the slot link at a predetermined angle.
[0017] In still further another aspect of the present invention the driving unit may include two hydraulic pressure cylinders having operating rods respectively, rear ends of which are pivotally connected to one portion and the other portion of the crank case respectively, and front ends of each operating rod are pivotally connected to one portion and the other portion of the slot link respectively.
[0018] In various aspect of the present invention, the variable compression ratio apparatus includes a connecting rod, a pin link, a slot link having a control slot, and a driving unit to be mounted in the crankcase without a size increase of the crankcase such that the compression ratio of the mixed gas is varied corresponding to driving conditions of the engine to improve the output and fuel efficiency thereof.
[0019] The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description of the Invention, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic diagram showing the crankcase of an engine in which an exemplary variable compression ratio apparatus according to the present invention is applied.
[0021] FIG. 2 is phased operation chart of an exemplary variable compression ratio apparatus according to the present invention in a low compression ratio condition.
[0022] FIG. 3 is phased operation chart of an exemplary variable compression ratio apparatus according to the present invention in a high compression ratio condition.
[0023] FIG. 4 is a diagram showing a position change of top dead center of a piston according to the position change of a slot link in an exemplary variable compression ratio apparatus according to the present invention.
[0024] FIG. 5 is a schematic diagram showing the crankcase of an engine in which an exemplary variable compression ratio apparatus according the present invention is applied.
[0025] FIG. 6 is a schematic diagram showing the crankcase of an engine in which an exemplary variable compression ratio apparatus according to the present invention is applied.
[0026] FIG. 7 is a schematic diagram showing the crankcase of an engine in which an exemplary variable compression ratio apparatus according to the present invention is applied.
[0027] FIG. 8 is a schematic diagram showing the crankcase of an engine in which an exemplary variable compression ratio apparatus according to the present invention is applied.
[0028] FIG. 9 is a schematic diagram showing the crankcase of an engine in which an exemplary variable compression ratio apparatus according to the present invention is applied.
[0029] It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment.
[0030] In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
[0032] The various embodiments of the present invention will be described more fully hereinafter with reference to the accompanying drawings.
[0033] FIG. 1 is a schematic diagram showing the crankcase of an engine in which an exemplary variable compression ratio apparatus according to the present invention is applied.
[0034] As shown in FIG. 1 , the exemplary variable compression ratio apparatus 1 according to the present invention is configured in an engine that receives an explosion force of a mixed gas from a piston 3 to rotate a crankshaft 5 to vary the compression ratio of the mixed gas.
[0035] The piston 3 reciprocates inside a cylinder 7 , and a combustion chamber is formed between the piston 3 , the cylinder 7 , and a cylinder head.
[0036] The crankshaft 5 receives the explosion force from the piston 3 to change the explosion force to a rotation torque and transfers it to a transmission. The crankshaft 5 is configured inside a crankcase 9 that is formed below the cylinder 7 .
[0037] The variable compression ratio apparatus 1 includes a connecting rod 11 , a pin link 13 , a slot link 15 , and a hydraulic pressure cylinder 17 as a driving unit to be configured inside the crankcase 9 .
[0038] Ends of the connecting rod 11 are respectively connected to the piston 3 and the pin link 13 so as to receive the explosion force from the piston 3 to transfer it to the pin link 13 .
[0039] That is, one end of the connecting rod 11 is rotatably connected to the piston 3 by a piston pin 19 , and the other end thereof is rotatably connected to the pin link 13 by a connection pin 21 to from a connection portion P 1 .
[0040] One end of the pin link 13 is connected to the connecting rod to receive the explosion force from the connecting rod 11 , and the other end thereof is rotatably connected to an opposite side of the weight and eccentric with respect to the center of the crankshaft 5 to form a rotation point P 2 .
[0041] Further, the lower end of the slot link 15 is fixed to one side of the lower portion of the crankcase 9 by a hinge block 27 and a hinge Hi, and a control slot (S) is formed along the length direction thereof to guide the connecting pin 21 that connects the connecting rod 11 with the pin link 13 .
[0042] That is, the control slot (S) has an arc shape having a predetermined curvature and guides the movement of the connecting pin 21 to change the moving track of the pin link 13 , and simultaneously changes the stroke of the piston 3 through the connecting rod 11 to vary the compression ratio of the mixed gas.
[0043] That is, in the driving unit, the hydraulic pressure cylinder 17 is configured between the slot link 15 and the crankcase 9 to vary the position of the control slot (S).
[0044] That is, the rear end of the hydraulic pressure cylinder 17 is fixed to one side inner surface of the crankcase 9 by a hinge H 2 , the front end of the operating rod 29 is fixed to the other side of the slot link 15 by a hinge H 3 , and the slot link 15 rotates based on the hinge HI point corresponding to the operation of the hydraulic pressure cylinder 17 to vary the position of the control slot (S).
[0045] Accordingly, the variable compression ratio apparatus 1 rotates the control slot (S) of the slot link 15 according to operation of the driving unit and the hydraulic pressure cylinder 17 that variably guides the movement of the connecting pin 21 and the pin link 13 such that the stroke of the piston 3 that is connected thereto through the connecting rod 13 can be changed to vary the compression ratio of the mixed gas.
[0046] The rotation angle of the above slot link 15 based on the hinge H 1 point can be predetermined by a person of ordinary skill in this art at their discretion according to the necessary performance of the engine.
[0047] FIG. 2 is phased operation chart of the present exemplary variable compression ratio apparatus according to the present invention in a low compression ratio condition, and FIG. 3 is phased operation chart of the present exemplary variable compression ratio apparatus according to the present invention in a high compression ratio condition.
[0048] That is, as shown in FIG. 2 and FIG. 3 , the slot link 15 is rotated corresponding to low and high compression ratios such that the phased crossing angle ( 0 ) between the connecting rod 11 and the pin link 13 is differently achieved to vary the compression ratio of the mixed gas and the stroke of the piston 3 .
[0049] The compression ratio variation of the mixed gas in the present exemplary variable compression ratio apparatus according to the present invention is detailed through the diagram of FIG. 4 that shows the position change of top dead center of the piston 3 according to the position variation of the slot link 15 .
[0050] “Y” of FIG. 4 denotes top dead center (TDC) of the piston 3 in a case in which the mixed gas is maximally compressed.
[0051] As shown in FIG. 4 , when the slot link 15 rotates in an anticlockwise direction, the compression ratio decreases to the low state such that the top dead center of the piston 3 is lowered from the base position. That is, “d” represents the distance between the base position and the low compression ratio position of top dead center as the slot link 15 rotates for the control slot (S) to move forward and the distance “d” increases such that the compression ratio decreases.
[0052] Accordingly, the exemplary variable compression ratio apparatus according to the present invention has a simple structure and varies the compression ratio of the mixed gas according to the driving conditions of the engine such that the output and fuel consumption efficiency can be improved.
[0053] FIG. 5 is a schematic diagram showing the crankcase of an engine in which an exemplary variable compression ratio apparatus according to the present invention is applied.
[0054] As shown in FIG. 5 , the exemplary variable compression ratio apparatus 1 according to the present invention has basically the same constituent elements as the first variable compression ratio apparatus, i.e., a connecting rod 11 , a pin link 13 , a slot link 15 , and a driving unit, and connection relationships thereof are identical.
[0055] However, in the variable compression ratio apparatus 1 according to the present exemplary embodiment, a hinge block 27 is fixed to the lower side of the crankcase 9 and a slot link 15 is connected to a hinge H 1 of the hinge block 27 , and there is a difference in that a rack portion 31 is formed in the upper end of the slot link 15 .
[0056] Also, the driving unit according to the present exemplary embodiment includes a motor M 1 that is mounted on the inner surface of the crankcase 9 , and a pinion 33 is disposed on the rotation shaft of the motor M 1 to be engaged with the rack portion 31 .
[0057] That is, there is a difference in that the slot link 15 is rotated by the motor M through the rack portion 31 that is engaged with the pinion 33 .
[0058] Further, in the variable compression ratio apparatus 1 according to the present exemplary embodiment, the compression ratio of the mixed gas is varied by the same principle as in the first exemplary embodiment, and therefore the detailed description thereof will be omitted.
[0059] FIG. 6 is a schematic diagram showing the crankcase of an engine in which an exemplary variable compression ratio apparatus according to the present invention is applied.
[0060] As shown in FIG. 6 , the exemplary variable compression ratio apparatus 1 according to the present invention has basically the same constituent elements as the first variable compression ratio apparatus, i.e., a connecting rod 11 , a pin link 13 , a slot link 15 , and connection relationships thereof are identical.
[0061] However, the present exemplary variable compression ratio apparatus 1 has a difference in the driving unit.
[0062] That is, a driving unit according to the present exemplary embodiment includes a motor M 2 with an eccentric cam 41 is fixed on the rotation shaft thereof is mounted on the inner side of the crankcase, and a link 45 on which a cam ring 43 into which the eccentric cam 41 is inserted is formed in one end thereof and the other end thereof is hinged to the other side of the slot link 15 by a hinge H 4 .
[0063] Accordingly, there is a difference in that the eccentric cam 41 moves the link 45 as much as the eccentricity amount by the operation of the motor M 2 to rotate the slot link 15 .
[0064] Further, in the variable compression ratio apparatus 1 according to the present exemplary embodiment, the compression ratio of the mixed gas is varied by the same principle as in the first exemplary embodiment, and therefore the detailed description thereof will be omitted.
[0065] FIG. 7 is a schematic diagram showing the crankcase of an engine in which an exemplary variable compression ratio apparatus according to the present invention.
[0066] As shown in FIG. 7 , the exemplary variable compression ratio apparatus according to the present invention 1 has basically the same constituent elements as the first variable compression ratio apparatus, i.e., a connecting rod 11 , a pin link 13 , a slot link 15 , and a driving unit, and connection relationships thereof are identical.
[0067] However, the present exemplary variable compression ratio apparatus 1 includes the slot link 15 that is configured on the lower side of the crankcase 9 through the driving unit.
[0068] That is, the driving unit according to the present exemplary embodiment includes a motor M 3 that is mounted on the inner side of the crankcase 9 by a motor bracket (MB), and the lower end of the slot link 15 is fixed to the rotation shaft (MS) of the motor M 3 .
[0069] Accordingly, there is a difference that in the driving unit, the motor M 3 rotates the rotation shaft (MS) to rotate the slot link 15 .
[0070] Further, in the variable compression ratio apparatus 1 according to the fourth exemplary embodiment, the compression ratio of the mixed gas is varied by the same principle as in the first exemplary embodiment, and therefore the detailed description thereof will be omitted.
[0071] FIG. 8 is a schematic diagram showing the crankcase of an engine in which an exemplary variable compression ratio apparatus according to the present invention is applied.
[0072] As shown in FIG. 8 , the exemplary variable compression ratio apparatus 1 according to the present invention has basically the same constituent elements as the first variable compression ratio apparatus, i.e., a connecting rod 11 , a pin link 13 , a slot link 15 , and a driving unit, and connection relationships thereof are identical.
[0073] However, there is a difference in that a variable compression ratio apparatus 1 according to the present exemplary embodiment includes a slot link 15 that is mounted on the inner side of the crankcase 9 through the driving unit.
[0074] That is, the driving unit according to the present exemplary embodiment includes a vane type of hydraulic pressure actuator (VA) that is mounted on the inner side of the crankcase 9 through a valve bracket (VB).
[0075] The vane type of hydraulic pressure actuator (VA) receives hydraulic pressure from an oil control valve (OCV), which is configured outside, to rotate the center shaft (VS) that is connected to the vane (V), and the lower end of the slot link 15 is fixed to the center shaft (VS).
[0076] Accordingly, in the driving unit, a vane type of hydraulic pressure actuator (VA) is operated to rotate the slot link 15 as much as the rotation angle of the center shaft (VS) thereof.
[0077] Further, in the variable compression ratio apparatus 1 according to the present exemplary embodiment, the compression ratio of the mixed gas is varied by the same principle as in the first exemplary embodiment, and therefore the detailed description thereof will be omitted.
[0078] FIG. 9 is a schematic diagram showing the crankcase of an engine in which an exemplary variable compression ratio apparatus according to the present invention is applied.
[0079] As shown in FIG. 9 , the exemplary variable compression ratio apparatus according to the present invention 1 has basically the same constituent elements as the first variable compression ratio apparatus, i.e., a connecting rod 11 , a pin link 13 , a slot link 15 , and a driving unit according to the first exemplary embodiment, and connection relationships thereof are identical.
[0080] However, a variable compression ratio apparatus 1 according to the present exemplary embodiment includes a slot link 15 that is mounted on the upper and lower sides of the inner part of the crankcase 9 through a driving unit.
[0081] That is, the driving unit according to the present exemplary embodiment includes two hydraulic pressure cylinders 51 and 53 that are respectively mounted on the upper and lower sides inside the crankcase 9 , and the hydraulic pressure cylinders 51 and 53 are respectively connected to the middle part and the lower part of the slot link 15 through the operating rods thereof.
[0082] That is, there is a difference that in the driving unit, the two hydraulic pressure cylinders 51 and 53 is respectively operated to move the position of the slot link 15 .
[0083] Further, in the variable compression ratio apparatus 1 according to the present exemplary embodiment, the compression ratio of the mixed gas is varied by the same principle as in the first exemplary embodiment, and therefore the detailed description thereof will be omitted.
[0084] For convenience in explanation and accurate definition in the appended claims, the terms “upper”, “lower”, “front”, “rear”, “outside”, “outwardly”, and “inner” are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.
[0085] The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. | A variable compression ratio apparatus for varying a compression ratio, may include a connecting rod that is connected to a piston to take a combustion force; a pin link, one end of which is eccentrically connected to a crankshaft and the other end of which is pivotally connected to the connecting rod to form a connection portion therebetween; a slot link including a control slot to receive and guide the connection portion along the control slot; and a driving unit coupled to the slot link and configured to move the control slot to control a position of the connection portion. | 8 |
BACKGROUND
[0001] The present invention relates to a detachable combination shoe-pedal assembly for use in cycling. More particularly, the invention relates to a pedal assembly that permits a cycling shoe-pedal assembly to operably engage and safely disengage the pedal crank arm of a bicycle or other pedal powered apparatus.
[0002] Many modern bicycles, including those intended for road racing, are designed to transfer and convert the linear forces applied by the cyclist into rotational motion of the crank arm and sprocket. In conventional bicycles, the forces generated by the cyclist are exerted through the pedal assembly in the vertical direction when the pedal is depressed by the rider's foot as well as lifted on the upstroke. A popular configurations for road racing is the clipless pedal system comprising a pedal with a receptacle adapted to receive a cleat mounted in the sole of a special cycling shoes. This cleat snaps into the pedal receptacle allowing the cyclist to connect a shoe directly to the pedal, and indirectly to the crank arms, with ease. The cyclist's foot then disengages the pedal system by rotating or displacing the shoe in a predefined manner or under the force of an accident, for example.
[0003] Although the clipless pedal system allows the operator's foot to quickly connect to and disconnect from the crank, the cleat and corresponding receptacle in prior art systems is located directly below the sole of the cycling shoe. The location of the cleat and receptacle below the cyclist foot detrimentally affect the performance in at least three ways: First, the prior art systems, which can be as much as an inch thick, reduce the ground clearance at the underside of the pedal, thereby reducing limiting the angle at which the bicycle may be simultaneously pedaled and turned. Second, the thickness of the cleat and receptacle system increases the riding height of the cyclist and the frame, thereby increasing aerodynamic drag and bicycle weight. Third, the force exerted by the foot of the cyclist is distributed over the relatively small area of the cleat which increases the pressure of the foot in immediate proximity to the cleat of the foot and causes discomfort to the cyclist.
[0004] U.S. Pat. Nos. 5,586,472 to Lin, 5,440,950 to Tranvoiz, and 5,315,896 to Stringer disclose detachable pedal assemblies in which a portion of the release mechanism is located in proximity to the crank arm. In each of these patents, the pedal is mounted either directly or indirectly into the crack through the spindle. The pedal remains rotatably affixed to the crank until a linear force co-parallel to the axis of the spindle is applied. Although these prior art pedal assemblies may be quickly attached to and removed from the crank arm, manual intervention is required without which the pedal cannot be engaged or disengaged. Moreoever, these pedal assemblies are designed to facilitate the assembly and disassembly of the pedal in connection with the storage and transportation of the bicycle. These pedal assemblies do not include means to attach a cycling shoe to the pedal and are, therefore, entirely unsuitable for road racing applications where it is necessary to both press down and lift up the pedal.
SUMMARY
[0005] The present invention overcomes the limitations of the prior art with a detachable pedal assembly in which the release mechanism is positioned adjacent to the axle that threadedly engages the bicycle pedal crank arm. Location of the release mechanism to the side of the pedal and away from the underside of the cyclist's foot allows (1) the rider to assume a lower riding position, thereby reducing the frame height and aerodynamic drag; (2) the bottom side of the pedal to be raised, thereby allowing for sharper turns of the bicycle; (3) the pedal to have a greater surface area, thereby reducing the pressure across the cyclist's foot; and (4) the rider visibility of the release mechanism during engagement, unlike prior art systems.
[0006] In one embodiment of the present invention, the detachable pedal assembly is comprised of an axle assembly, binding assembly, and connecting means. The axle assembly is comprised of an axle adapted to threadedly engage the bicycle pedal crank arm. The binding assembly is comprised of a pedal through which the cycling shoe applies force to drive the bicycle. The connecting means is comprised of a bearing and releasable coupling means, the connecting means being substantially interposed between the pedal crank arm and the binding assembly in the lateral direction. Although the bearing and releasable coupling means may be affixed to either the axle assembly or the binding assembly, it is important that the releasable coupling means rigidly hold the binding assembly to the axle assembly until a force equal to or greater than a predetermined force threshold is applied, at which point the release coupling means responds by automatically disengaging the binding assembly from the axle assembly. In this manner, a cyclist may exert force on the pedal assembly without disengaging the pedal crank arm unless the cyclist chooses to disengage the binding assembly from the axle assembly. In some embodiments, the shoe-pedal assembly may be automatically disengaged from the bicycle crank if the cyclist befalls adverse circumstances.
[0007] In some embodiments of the present invention are designed with offset between the pedal of the binding assembly and the axle assembly to position the ball of the cyclist's foot at the axis of the axle. Still other embodiments adapted primarily to bicycle road racing applications include shoe fastening means permitting the cycling shoe to be affixed to the pedal assembly, thereby allowing the cyclist to drive the bicycle by pushing against the pedal in the down stroke as well as pulling on the pedal during the upstroke. The shoe fastening means may be used in combination with a force-responsive locking means that determines the force necessary to release the binding assembly from the axle assembly.
[0008] The shoe-pedal assembly in preferred embodiments is made to engage and disengage the axle mounted on the bicycle pedal crank assembly in the vertical direction, while other embodiments permit the binding assembly to engage and disengage the axle in the other directions or manners. The binding assembly may be made to alternatively engage or disengage the axle by means of one or more forces including rotational forces or linear forces applied in the horizontal or vertical plain.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is an exploded view of the detachable pedal assembly including the axle assembly, connecting means, and binding assembly of the present invention.
[0010] [0010]FIG. 2 is a cross-sectional view in a vertical plane through the axis of the axle in the preferred embodiment of the detachable pedal assembly.
[0011] [0011]FIG. 3 is an interior side view of the binding assembly of the preferred embodiment attached to the shoe.
[0012] [0012]FIG. 4 is a view of the underside of the binding assembly and axle assembly, attached to the shoe and mounted into the crank arm, of the preferred embodiment.
[0013] [0013]FIG. 5 is a front side view of the shoe with binding assembly, axle, and crank arm of the preferred embodiment in the locked position.
DETAILED DESCRIPTION
[0014] The present invention pertains to a detachable pedal assembly permitting a cycling shoe to operably engage and safely and efficiently disengage the pedal crank arm of a bicycle or other pedal powered apparatus. The pedal assembly effectively transmits the forces exerted by the cyclist's shoe to the pedal crank arm, allowing the cyclist to both push down on the pedal as well as lift up on it so long as the forces are within a predetermined range. For safety purposes, the cyclist's shoe-pedal assembly may be released from the pedal crank when the forces reach an unsafe level as in an accident or collision, for example.
[0015] The accompanying figures depict embodiments of the detachable pedal assembly of the present invention, and features and components thereof. With regard to means for fastening, mounting, attaching or connecting the components of the present invention to form the apparatus as a whole, unless specifically described otherwise, such means are intended to encompass conventional fasteners such as machine screws, machine threads, snap rings, hose clamps such as screw clamps and the like, rivets, nuts and bolts, toggles, pins and the like. Components may also be connected by friction fitting, or by welding or deformation, if appropriate. Unless specifically otherwise disclosed or taught, materials for making components of the present invention are selected from appropriate materials such as metal, metallic alloys, natural or synthetic fibers, plastics and the like, and appropriate manufacturing or production methods including casting, extruding, molding and machining may be used.
[0016] Any references to front and back, right and left, top and bottom, upper and lower, and horizontal and vertical are intended for convenience of description, not to limit the present invention or its components to any one positional or spatial orientation.
[0017] Referring to FIGS. 1 and 2, an exploded view and cross section of the detachable pedal assembly including the axle assembly, bearing, and binding assembly of the present invention are illustrated. The axle assembly 124 in this embodiment is comprised of an axle 102 , a bearing 103 , and an optional spacer 104 .
[0018] The axle 102 is comprised of a pedal crank connecting portion 109 and a bearing connecting portion 110 . The crank connecting portion 109 preferably includes a standard thread pattern adapted to securely engage the corresponding threads 107 of the crank arm 106 . The bearing connecting portion 110 is characterized by a diameter substantially equal to the diameter of the inner surface 114 of the bearing 103 such that the axle 102 and bearing 103 are securely affixed to one another after installation of the bearing 103 and during operation of the bicycle. After installation, the bearing 103 preferably abuts a retainer 111 which, in this embodiment, is a circularly symmetric lip used to prevent the bearing 103 from disengaging the axle 102 in the direction away from the crank arm 106 . The retainer 111 preferably includes two parallel planar faces 111 A that adapted to receive a wrench used to apply the torque necessary to engage and disengage the threads of the crank connecting portion 109 to the crank arm 106 . In other embodiments, the bearing connecting portion 110 and bearing 103 may include threads, set screws, permanent welds, bonding agents, or friction fitting to prevent the unintended separation of the bearing 103 from the axle 102 .
[0019] The bearing 103 represents any one of a number of alternative structures for providing a substantially friction free rotation of the binding assembly 101 relative to the axle 102 . In general, the bearing 103 includes an inner surface 114 and outer surface 113 that rotate relative to one another about the bearing axis that coincides in this embodiment with the axis of the axle 130 . The internal construction of bearings is well document and unnecessary for an understanding of the design, assembly and operation of the present invention.
[0020] In the preferred embodiment, the bearing 103 is a sealed thrust bearing capable of withstanding rotational forces about the axle axis 130 as well as torsional forces exerted by the binding assembly 101 discussed in more detail below. Although aircraft quality bearings are suitable, the bearing used in the present invention is subjected to relatively low speeds, typically on the order of 120 rpm in this embodiment. One skilled in the art will recognize that other standard bearings and custom bearings including various ball bearings, baring faces, and lubricants may be equally suitable with appropriate modification to the axle 102 and binding assembly 101 .
[0021] The detachable pedal assembly of the present invention may further include a spacer 104 in conjunction with the axle 102 in order to tailor the height of the axle 102 away from the pedal crank arm 106 . The thickness of the spacer 104 will, in general, depend on the particular preferences of the rider.
[0022] Also illustrated in FIG. 1 is the binding assembly 101 comprised of a releasable coupling means and a pedal. In the preferred embodiment, the releasable coupling means is a clasp or receptacle in the shape of an arcuate cup comprised of the first structure 115 , second structure 117 , and third structure 118 . The first, second, and third structures are designed with the precision and tolerance necessary to receive the bearing 103 and limit the relative movement of the binding assembly 101 and bearing 103 in non-vertical directions. In particular, the width between the first structure 115 and the second structure 117 must be substantially equal to the depth of the outer surface 113 of the bearing 103 in order avoid a loose fit that may reduce the ability of the binding assembly 101 to remain operatively engaged to the bearing 103 when upward force is applied to the binding assembly 101 .
[0023] The clasp should also be constructed of a substantially rigid material such as steel, titanium, aluminum, chromoly, or carbon fiber, for example, sufficient to withstand the static and dynamic forces exerted by a cyclist under stringent riding conditions. The clasp may further include portals 122 A, 122 B for allowing the egress of dirt from the interior side of the clasp and to permit visual alignment of the binding assembly 101 with the axle assembly 124 .
[0024] The binding assembly 101 further includes a pedal 120 for engaging the cycling shoe 140 and transferring the forces exerted by the cyclist to the axle 102 . In the preferred embodiment, the pedal 120 is comprised of a substantially flat plate rigidly affixed to the releasable coupling means, although the plate may assume alternative shapes necessary for adaptation to various cycling shoes. In some embodiments, the pedal 120 further includes shoe fastening means 121 for securing the cycling shoe 140 to the binding assembly 101 , as discussed below in more detail.
[0025] In some embodiments, the shoe fastening means may include a receptacle adapted to receive alternate forms of detachable pedal systems including the numerous clipless pedals on the market today.
[0026] The thickness of the pedal 120 will depend on the material selected but, in general, should be a thin as reasonably possible in order to increase the ground clearance with the bottom of the pedal 120 , important during high speed angled turning or maneuvering. The pedal 120 should be constructed of a substantially rigid material such as steel, titanium, aluminum, chromoly, or carbon fiber, for example, sufficient to withstand the static and dynamic forces exerted by a cyclist under stringent riding conditions.
[0027] An important feature of some embodiments of the present invention is the force-responsive locking means that firmly retains the binding assembly 101 engaged with the axle 102 until a predetermined force is exceeded. Once the predetermined force is exceeded, for example, where the cyclist dismounts the bicycle or is in an accident, the binding assembly 101 detaches or otherwise breaks-away from the axle 102 . The locking means is preferably designed to allow detachment the binding assembly 101 in a non-destructive manner, thus allowing the binding assembly 101 to later re-engage the axle 102 .
[0028] Still referring to FIGS. 1 and 2, the force-responsive locking means in the preferred embodiment is comprised of a detent device with a spring-load ball bearing 127 in the axle 102 that engages a corresponding recess 116 B in the binding assembly 101 . The ball bearing 127 is held in position by the retaining washer 131 on one side and the set screw 126 , spring 128 , and plate 129 on the other.
[0029] To engage the binding assembly 101 and axle assembly 124 in this embodiment, the cyclist lowers the binding assembly 101 on to the axle assembly 124 with the clasp vertically aligned with the bearing 103 . As the binding assembly 101 is lowered onto the axle 102 , the ball bearing 127 is guided by the race 116 A until the clasp fully engages the bearing 103 , at which point the ball bearing 127 seats into the recess 116 B. After being seated into the recess 116 B, the ball bearing 127 , under the force of the spring 128 , prevents the binding assembly 101 from being lifted off of the axle 102 during normal operating conditions. The force exerted by the spring may be adjusted as desired up to several hundred pounds using the set screw 126 that threadedly engages the axle within the recess 125 .
[0030] In this preferred embodiment, the binding assembly 101 is permitted to disengage the axle by means of a linear force applied in the vertical direction, the direction normal to the pedal surface 119 . One skilled in the art will recognize that alternative embodiments of the present invention may be adapted to permit detachment of a binding assembly if a linear or rotational force is applied in one or more different directions. The present invention would be equally applicable to an apparatus in which the cyclist disengaged his foot by applying a twisting force about the pedal or a linear force outward in the direction of the axle axis, for example.
[0031] Referring to FIG. 3, an interior side view of the binding assembly of the preferred embodiment is illustrated. The shape of the arcuate cup of the releasable coupling means is clearly visible, including the radial contour of the second structure 117 and third structure 118 . Located at the center of these concentric surfaces is the recess 116 B corresponding to the ball bearing 127 located on the axis 130 of the axle 102 . Leading to the recess 116 B is the race 116 A which approximately defines the direction that the binding assembly 101 is directed to engage and lock the axle assembly 124 .
[0032] Also illustrated in the preferred embodiment is the guide 115 A which assists the axle 102 into the arcuate cup. The guide 115 A is elevated above the surface 115 by a distance represented by the depth of the surface 115 B, which is substantially equal to the thickness of the retainer 111 .
[0033] Referring to FIG. 4, a view of the underside of the binding assembly and axle assembly when mounted into the pedal crank arm according to the preferred embodiment is illustrated. In the preferred embodiment, the pedal 120 has a width and length roughly corresponding to the ball of the cyclist's foot through which the energy is transferred during riding.
[0034] In some embodiments, the pedal 120 includes shoe fastening means for securing the cycling shoe to the binding assembly 101 . The shoe fastening means may comprise holes or slots 121 sized and positioned to receive screws or bolts capable of rigidly securing a cycling shoe to the binding assembly during cycling. Of course, the screws, bolts or equivalent means may be detached, thereby allowing the shoe or binding assembly to be replaced. The pedal 120 may further comprise float means permitting the cycling shoe to “float,” i.e., move in an angular and lateral direction relative to the pedal 120 to increase comfort and efficiency for the rider. The float means may be achieved in some embodiments a hinge, bearing, pivot, articulated joint, or equivalent means.
[0035] One skilled in the art will recognize the pedal 120 of the present invention also allows the cyclist to walk with the binding assembly 101 attached to the cycling shoe with minimal discomfort or damage to the binding assembly 101 . Unlike the prior art pedal assemblies, the cleat is not located underneath the rider's shoe where it would otherwise be subjected to the wear and tear that occurs when the rider walks on the cleats when dismounted from the bicycle. In some embodiments, the underside of the pedal 120 may further include a durable sole made or rubber or equivalent material for reducing wear of the pedal 120 and protectively concealing the screws or bolts that engage the cycling shoe.
[0036] [0036]FIG. 5 is a front side view of binding assembly, axle, and crank arm of the preferred embodiment in the locked position. As shown, the clasp receives a portion of the axle assembly 124 , in the preferred embodiment, thereby engaging the axle assembly 124 in a manner than supports the transfer of force from. the cyclist's foot to the crank arm 106 .
[0037] One skilled in the art will recognize that the advantage of interposing the detachable interface formed by the clasp and the axle assembly 124 between the rider's foot and the crank arm 106 , the height of the pedal surface 119 relative to the axle axis 13 O may be adjusted to improve the performance, efficiency, and performance of the cyclist. In particular, the offset position of the pedal surface 119 in the preferred embodiment is such that the axle axis 130 approximately coincides with the ball of the rider's foot. This configuration may be optimized according to biokinetics in a manner that was previously unavailable in prior art detachable pedal systems because of the thickness of the cleat system that occupied space below the pedal.
[0038] Although the above description contains many specifics, these should not be construed as limiting the scope of the invention, but rather as merely providing illustrations of some of the presently preferred embodiments of this invention.
[0039] 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. | A detachable pedal assembly including an automatic release mechanism that is positioned approximately between the pedal and crank arm is disclosed. The detachable pedal assembly in one embodiment comprising an axle assembly including thrust bearing and threads to engage the crank, a binding assembly including a pedal to which the cyclist applies force and clasp that detachably receives the thrust bearing, and a force-sensitive locking means that holds the binding assembly in operational engagement to the axle assembly until a predetermined force is applied, at which time the binding assembly automatically releases the axle assembly to permit the cyclist to dismount or avoid injury in an accident. The position of the release mechanism to the side of the binding assembly permits the binding assembly to be offset from the axle axis, thereby improving increased riding efficiency, lower aerodynamic drag, and increased turning clearance. | 1 |
FIELD OF THE INVENTION
The present invention relates to apparatus for stacking short logs or bolts in the form of a lineal stack several bolts in height. In another aspect, the invention relates to apparatus for de-limbing a cut tree, cutting it into short logs, and then stacking it as aforesaid.
BACKGROUND OF THE INVENTION
The invention has been developed in connection with processing aspen trees and stacking the produced short logs (called "bolts") in logging operations conducted in Northern Alberta. The conventional steps practiced and the equipment used in that operation will now shortly be described, to identify some of the shortcomings that the present invention solves. However, in so doing it is to be understood that the invention is not to be limited in application to processing aspen.
In connection with such logging, the trees are cut and then skidded to the side of the logging road. Here they are placed with their butt ends at the road edge and their stems extending generally perpendicularly from the road. A machine, referred to as a de-limber, comes along and grasps each tree with two annular sets of arms. The outermost arms have de-limbing knives on their edges and are carried by a telescoping boom. The innermost arms are carried by the machine and are stationary. The outermost arms grasp the tree, part way up its stem, and place the butt into the innermost arms, which firmly grasp the butt. The outermost arms are then partially loosened and are stroked up the tree by the boom. It may require two or more strokes of the boom to de-limb the stem to a pre-determined diameter. The outermost arms are then further closed, to cut off the remaining unscraped tree top. The outermost arms are then moved back partway along the stem, the innermost arms are released and the stem is dropped to the ground.
At this stage, the de-limbed stems may be loaded onto a truck and sent to the mill for further processing. Or alternatively, they may be further processed at the logging site by cutting them into 8 foot long bolts.
The bolt-forming step in the field involves use of a second machine, referred to as a "slasher". The slasher has an arm that picks up the de-limbed stem with a grapple, rotates it through 90° so that it is aligned with the road, and then advances the stem longitudinally until its end contacts a butt plate. A cutting element, spaced 8 feet from the butt plate, then moves into engagement with the stem and cuts it to form a bolt. The bolt drops into a "basket". The advancement and cutting process is then repeated. Once the basket is filled with bolts, the slasher arm is actuated to pick up the logs in the basket, rotate them through 90°, and then place them in piles on the road edge, ready to be loaded on a truck.
From the foregoing, it will be noted that the conventional system involves a significant number of machine movements, such as:
picking up the tree from the skidded tree pile;
two-way travel of the tree stem during delimbing;
laying the de-limbed stem down in a separate pile;
picking up the de-limbed stem with the slasher and rotating it 90° to align it with the slasher; and
positioning the basket load of bolts at the side of the road.
It is a preferred objective of the present invention to provide apparatus and processing steps which simplify the operations of de-limbing and cutting the trees to form bolts and assembling the bolts in a stacked condition amenable for loading onto trucks.
It is the main objective to provide a novel system for stacking bolts.
SUMMARY OF THE INVENTION
In a first aspect of the invention, there is provided a movable apparatus for stacking bolts to form an elongated linear stack. The apparatus, termed a "stacker", is adapted to be moved along a windrow of trees that are in the process of being converted into bolts. The stacker is operative to receive these bolts and stack them in an orientation such that they are transverse to the longitudinal axis of the stack to be created. The formed stack issues from the open rear end of the ongoing stacker and is left on the ground in the form of an elongated, linear stack, one bolt in width and several bolts in height.
The stacker comprises means, such as a receiving bin or hopper, that function to position one or more received bolts adjacent to ground surface in an orientation that is generally perpendicular to the direction of advance of the stacker. Means, such as a plunger, are provided to bias the so-positioned bolts rearwardly, while preserving their orientation. The stacker further comprises means, such as a stacking bin, for collecting the bolts and depositing them on the ground in the form of a stack. Preferably, the stacking bin is open-bottomed (at least at its rear end) and has an open rear end. It comprises a front wall and a pair of spaced, rearwardly extending, parallel side walls. The side walls are spaced apart a distance that is just greater than the length of the bolts, so the walls are operative to confine the bolts at their ends. The front wall has an inlet located adjacent ground surface. The inlet communicates with the hopper and is adapted to enable entry of the bolts, biased by the plunger, into the stacking bin chamber.
The following features of the stacker will be noted:
Except when first beginning, the bolts being biased into the stacking bin encounter a stack of bolts already in the bin chamber. This stack of bolts has frictional contact with the ground surface. Thus, the newly entering bolts encounter resistance and have to be driven with some force into the stack;
The bolts in the stacking bin are closely confined at each of their ends by the side walls of the bin; and
The bolts being introduced into the bin are entering at or adjacent to ground surface (or at the base of the stack).
The result of combining these features is that the entry of new bolts into the stack in the bin induces a "boiling up" action of the bolts. The bolts, which otherwise would have a tendency to "jack-straw", self-align themselves in the boiling-up action and form a generally uniform and neat stack of parallel members having each of their ends generally in a common vertical plane.
In a second aspect of the invention, a novel processing assembly is combined with the stacker to yield a novel bolt-forming and stacking assembly. The processing assembly comprises:
A conventional articulated arm and grapple (known as a "knuckle boom log loader"), which is adapted to reach out and grasp one or more of the tree stems by their butt ends and drag them inwardly to position the butt ends over a processing head, at which point the grapple may then be opened to drop the butt ends into engagement with the processing head; and
A processing head that is mounted on a pivoting and rotating support, so that the head may align itself with the one or more stems being processed. The head is adapted to engage and longitudinally advance the stem; simultaneously de-limb it; terminate advancement when the proper bolt length extends past a cutting element; and pivot the cutting element through the advanced stem to cut and form the bolts. More particularly, the processing head comprises: a pair of driven rolls that clamp onto the dropped stem and advance it axially; de-limbing means that encircle the advancing stem and scrape off the branches; a cutting element, such as a pivoting chain saw or circular saw, that is adapted to sever the stem; and means for interrupting the advance of the stem when the desired length has passed the saw, whereby the rolls are stopped and the saw is pivoted to cut and form the bolts, which drop into the hopper.
It will be noted that the bolt-forming and stacking assembly is characterized by the following advantages:
The tree stem is handled only once, by advancing it longitudinally;
The stem is de-limbed and cut into bolts in the course of the single longitudinal movement of the stem;
The bolts remain aligned with the travel of the stem, so no re-orientation is involved;
The processing of stems does not involve the grapple arm, so the operator may use the latter to pick up a second set of stems as the first set is being processed; and
The stack of bolts issue from the rear end of the stacker as it moves ahead, without any requirement for machine movements (such as lifting and rotating baskets of bolts, as is the case in the prior art).
Broadly stated, the invention is an apparatus for stacking de-limbed logs to form a linear stack, comprising: means for receiving the bolts and positioning them adjacent ground surface in generally perpendicular relation to the longitudinal axis of the stack to be created; means for biasing the bolts rearwardly out of the positioning means while maintaining their orientation; and means for collecting the bolts, as they are biased out of the positioning means, and depositing them on the ground in the form of a stack as aforesaid, said collecting means being positioned contiguously and rearwardly of the positioning means whereby the bolts being biased are forced into the base of the stack being collected, said collecting means being adapted to confine the bolts therein at their ends.
DESCRIPTION OF THE DRAWINGS
FIGS. 1-7 are schematic side sectional views showing the operation of the stacker;
FIG. 8 is a perspective view of the stacker, showing the hopper and stacking bin;
FIG. 9 is a side sectional view of the stacker, taken along the line A--A of FIG. 7;
FIG. 10 is a top plan view of the bolt-forming and stacking assembly;
FIG. 11 is a side view of the assembly of FIG. 9;
FIG. 12 is an end view showing the kicker assembly;
FIG. 13 is an end view showing the de-limbing assembly;
FIG. 14 is a top plan view showing the roll assembly;
FIG. 15 is a side view showing the roll assembly;
FIG. 16 is an end view showing the cutting assembly;
FIG. 17 is a side view showing the processing head; and
FIG. 18 is a top plan view showing the processing head.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The illustrated bolt-forming and stacking assembly 1 comprises a tractor 2, a grapple arm 3 mounted on the rear end of the tractor, a hopper 4 and stacking bin 5 which are carried by a wheel-supported skid frame 6 that is hitched to the tractor 2, and a processing head 7 carried by the front end of the skid frame 6. These components form a unitary assembly that may be moved along a logging road or the like.
The tractor 2 has a conventional motor and hydraulic system for powering and controlling the components. It is within the ordinary skill of the art to design and provide these systems. Therefore they will not be described herein, as they do not go to the essence of the invention. However, the disclosure does indicate the functions to be carried out and the operational and sequential features that are involved.
As stated, the tractor 2 carries a conventional grapple arm 3. This arm is mounted on a turntable 8, for rotation about a vertical axis. It can also be extended or contracted and raised or lowered, as required. At its outer end, the arm carries a conventional log-loading grapple 9. The arm is equipped with actuating cylinders and control circuits (not shown), whereby the operator may control the arm from the cab 10. The arm may be used to reach outwardly to the edge of the logging road, grasp one or more butt ends of the trees extending therefrom, lift the grasped butt(s), drag the trees inwardly so that the butt ends overlie the processing head 7, and drop the grasped ends so that they engage the processing head 7.
The skid frame 6 is suspended at its front end from the tractor 2 by a pivoting linkage assembly 11. More particularly, links 12 are pivotally connected to each of the tractor and skid frame, to enable the front end of the skid frame to be raised or lowered. A hydraulic cylinder 13 interconnects the tractor hitch 14 with the skid frame and, when actuated, the cylinder is operative to raise or lower the skid frame. At its rear end, the skid frame is pivotally interconnected with the rear wheels 15 by a link assembly 16. A hydraulic cylinder 17 is pivotally connected between the skid frame and link assembly 15 and functions to raise or lower the rear end of the skid frame, as required. A pair of stabilizer legs 18, actuated by cylinders l8a, are mounted to the two sides of the skid frame at its front end, for stabilizing the frame when the apparatus is working. In summary, means are provided for lowering the skid frame 6 to the ground and stabilizing it. The skid frame and stabilizer legs can also be raised, to enable the assembly 1 to move along the road.
Suitable hydraulic circuits (not shown) are provided for controlling the cylinders 13, 17, 18a from the cab 10.
The processing head 7 is mounted on a transverse support beam 19 which, in turn, is mounted on the front end of the skid frame 6 by a gimbal joint 20. The gimbal joint 20 enables the head 7 to rotate in a horizontal plane and to pivot in a vertical plane, within limits dictated by the stops 21. As a result, the head 3 may swivel and pivot as required to align itself with the tree stem being processed.
More particularly, the gimbal joint 20 comprises a turntable 22 mounted on the skid frame 6. The turntable 22 carries a pair of upstanding, spaced apart lugs 23. A wrist pin 24 is supported by the lugs 23 and is free to pivot. The main support beam 19 of the processor head is mounted on the wrist pin 24.
The processing head 7 comprises a linear array of components carried by the support beam 19 and adapted to engage the tree stem being processed, advance it longitudinally, de-limb it as it advances, cut it into de-limbed bolts of pre-determined length, and discard the undesired small diameter end of the stem. These components perform their functions during a single pass or advancement of the stem.
More particularly, at its outermost end, the head 7 comprises a kicker arm assembly 25 adapted to eject the tree top upward and away from the assembly 1. Having reference to FIGS. 16 and 17, the kicker arm assembly 25 includes a pair of kicker arms 25a, which are pivotally mounted on a rotatable pivot shaft 26 carried by a housing 27 secured to the main support beam 19. A hydraulic cylinder 28 is pivotally connected between the housing 27 and a lug 29 connected with the pivot shaft 26. Extension of the cylinder 28 will cause the kicker arms 25 to rotate upwardly about the shaft 26, to throw the tree top away.
The head 7 further has a de-limbing assembly 30 mounted on the main support beam 19. The de-limbing assembly comprises a pair of de-limbing plates 31 having knife edges arranged in the form of a shallow V. The plates 31 support the tree stem from below as it is being advanced. A first upstanding curved de-limbing arm 32, having a knife edge, is pivotally mounted on the rod 33 of a hydraulic cylinder 34, which is pivotally mounted to a plate 35 secured to the main support beam 19. A link 36 is pivotally connected between the first de-limbing arm 32 and a second similar de-limbing arm 37. Extension of the rod 33 will cause the de-limbing arms 32, 37 to move together and rotate into close engagement with the tree stem being processed.
Inwardly of the de-limbing assembly 30, the head 7 has a feed roll assembly 40 mounted on the support beam 19. The feed roll assembly 40 comprises a pair of vertical studded rolls 41, each rotatably mounted in a carrier frame 42. Each carrier frame 42 is pivotally secured to one end of an actuating hydraulic cylinder 43. The two carrier frames 42 are joined by a pivotally mounted equalizer link assembly 44. Extension and contraction of the roll cylinder 43, coupled with the action of the equalizer link assembly 44 and the pivot connections involved, will cause the two rolls 41 to open and close proportionately and equally. A drive motor 45 powers each roll 41.
Inwardly of the feed roll assembly 40, the processor head 3 comprises a cutting assembly 50 which can be actuated to cut through the tree stem being processed. The cutting assembly 50 shown comprises a circular saw 51 mounted on and driven by the shaft 52 of a hydraulic motor 53. The motor 53 and saw 51 are mounted on a pivoting arm 54 supported by the main support beam 19. A hydraulic cylinder 55 is pivotally connected between the support beam 19 and arm 54, for swinging the saw 51 into cutting engagement with the tree stem.
A photo cell assembly 60 is provided to sense the innermost end of the advancing stem. The photo cell assembly 60 is connected with means (not shown) operative to actuate the cutting assembly 50 and temporarily stop the rolls 41.
Suitable hydraulic circuits (not shown) are provided for actuating the kicker arm assembly 25, de-limbing assembly 30 and roll assembly 40 from the cab 10.
Turning now to the stacker 70, it comprises a hopper 4 and stacking bin 5.
The hopper 4 is generally rectangular and open-topped. It is positioned below and contiguous to the processing head 7, so that the bolts 71 drop into it as they are cut. The side walls 72 of the hopper are spaced apart so that the bolts 71 are loosely confined at their ends. Typically, the spacing of the side walls can be 9 feet for 8 foot long bolts. The upper ends of the hopper front and side walls 73, 72 are inwardly sloping so that they are adapted to centralize the bolt in the hopper chamber 74. The hopper is reinforced and contained by the skid frame 6. A reject bucket 100 is pivotally mounted to one of the side walls 72. The bucket 100 can be rotated inwardly by a hydraulically actuated cylinder (not shown) to a position at the base of the inwardly sloping front wall 73 of the hopper. There it can intercept a deformed or otherwise defective bolt and throw it away from assembly 1.
In operation, the hopper 4 is adapted to receive and position the bolts 71 adjacent the ground surface on which the skid frame 6 rests. When so positioned, the bolts are oriented generally perpendicularly to the longitudinal axis of the stack that is to be formed.
A broad-faced plunger 75 is centrally positioned at the base of the hopper chamber 74. The plunger 75 is actuated by the rod end of a hydraulic cylinder 101.
In operation, the plunger 75 functions to bias rearwardly any bolts 71 present in the hopper chamber 74. The confining hopper side walls 72 and the broad face 77 of the plunger 75 cooperate to maintain the orientation of the bolts.
The stacking bin 5 is contiguous to and rearward of the hopper 4. They share a common wall 78. The stacking bin 5 is also rectangular in configuration, having parallel side walls 79. The side walls 79 are spaced apart sufficiently so that they loosely confine the bolts 71. The bin 5 is open-ended at the rear and open-bottomed. (Note that, while the drawings show the stacking bin 5 open throughout its height at the rear and open-bottomed throughout most of its length, it is only necessary that the stack 80 formed in the chamber 81 of the stacking bin 5 be able to pass out the rear of the bin and make contact with the ground as it leaves. So the bin can have a floor along most of its length and a rear end wall extending part way down from its upper edge.)
The front wall 78 of the stacking bin 5 forms an aperture 82 at its lower end. The aperture 82 extends the width of the stacking bin 5, so that it is adapted to enable entry therethrough of the bolts being biased rearwardly. A hinged, segmented, one-way closure 83 permits the bolts to move from the hopper chamber 74 into the stacking bin chamber 81, but prevents them returning in the other direction.
From the foregoing, it will be noted that the stacking bin 5 is adapted to collect the bolts being biased rearwardly and to form them into a stack 80, at least the rear part of which is in frictional engagement with the ground surface. When the stacking bin 5 is moved ahead, the stack 80 is left deposited on the ground and joins other bolts already deposited there to form an elongated lineal stack.
In the operation of the assembly, the grapple arm 3 grasps a tree stem and drops its butt end into the gap between the drive rolls 40. The de-limbing assembly 30 is activated to bring the knife arms 32, 37 and knife plates 31 into pressing engagement with the stem. The rolls 40 are also clamped onto the stem and then activated to advance the stem end toward the photo cell assembly 60. When the assembly 60 senses that the stem has reached it, the drive rolls 40 are stopped and the cutting assembly 50 is activated to cut through the stem and form a bolt 71. Some deformed bolts are discarded by the reject bucket 100. The remaining bolts drop into the hopper chamber 74 and are guided to assume a position, at the base of the chamber 74, in which they are generally perpendicular to the longitudinal axis of the stack 80 to be formed. The plunger 75 then is activated to bias the bolts rearwardly out of the hopper 5 and force them into the base of the stack 80 already in the bin chamber 81. The bolts so biased cause a "boiling up" of bolts within the bin chamber 81. The combination of confining the bolts at their ends, providing resistance to their entry into the stack by having it in frictional contact with the ground, and injecting the bolts into the base of the stack, induces a boiling up of the bolts, at the front end of the stack, that causes them to maintain a parallel alignment. Returning to the stem being processed, when the small diameter top end is reached, the kicker arm assembly 25 is activated to discard it.
The scope of the invention is set forth in the claims now following. | The stacker comprises a receiving bin adapted to position bolts close to the ground in an orientation that is perpendicular to the direction of advance of the stacker. The bin has side walls that closely confine the two ends of the bolts. A reciprocating plunger at the base of the bin biases the bolts rearwardly through an aperture into a stacking bin that trails the receiving bin. The stacking bin is open at the rear and at the bottom. Its parallel side walls closely confine the ends of the bolts collecting therein. The bolts biased rearwardly by the plunger are forced into the base of the stack in the stacking bin. The combination of the resistance of the ground-engaging stack, the confinement by the side walls, and the forced introduction of bolts into the base of the stack, induces a "boiling up" action of the bolts at the front end of the stack whereby they self-align themselves into a parallel state. When the bins are moved ahead, they leave behind an elongated stack of bolts. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the general field of infrared detectors, more particularly to the use of tuned cavities.
2. Description of the Prior Art
FIG. 1 is a schematic diagram of a Fabry Perot interferometer. Its basic components are a pair of transparent plates 5 and 6, spaced a few millimeters apart, whose inner surfaces have been coated with a thin film of metal which reflects almost all of a light beam that may be incident upon it but does transmit a small proportion thereof. Typically about 90% of the light is reflected and about 10% is transmitted, absorption being negligible.
Thus about 10% of light beam 1, entering the system at other than normal incidence, will enter the inter-plate cavity where it will be successively transmitted and reflected at both of the inner surfaces. It is readily seen that the transmitted beams that emerge on the far side of plate 6 (designated 2,3,4 in FIG. 1) are all coherent relative to each other and adjoining beams differ in phase from one another by the same amount. If such beams are caused to converge by means of a lens (not shown, but located to the right of plate 6) they will form interference fringes, dark where they were out of phase, light where they reinforced one another.
Interferometers of the type illustrated in FIG. 1 can have very high resolving power but they are very sensitive to a number of factors. These include the reflectivity and optical finish of the surfaces involved and establishment and maintenance of parallelism. Additionally, small variations in optical path length within the cavity that may result from temporary or permanent inhomogeneities of the material contained in the cavity, must be avoided.
A number of these problems are removed or mitigated if the plates of the interferometer are concave, as illustrated in FIG. 2. Light beam 21 enters the cavity by passing through partially reflecting surface 25. After making four passes back and forth between the two concave surfaces it has reached region 22, which is approximately its point of entry. After four more passes it is back at 22 again, and so on. This arrangement of two concave plates need not be perfectly aligned to still function. Nor is it as sensitive to external vibration as the parallel plate version.
An optically equivalent version of the double concave structure can be constructed by using a single concave plate in conjunction with a planar mirror. A virtual image of the concave surface is created by the planar mirror so a light beam will end up in the same spot within the cavity after every eight passes. An interferometer of this type forms the subject matter of the present invention and may be looked at as a resonant cavity in the microwave sense.
We are not aware of any prior art relative to infrared radiation detectors that is based on the use of a resonant cavity. Cole (U.S. Pat. No. 5,286,976 February 1994) teaches a detector that is partly transparent to infrared and is backed up by a mirror so it receives additional input from the reflected beam, making it, in effect, a two pass cavity. This is not, however, a resonant cavity and Cole's detector is sensitive over a wide range of infrared wavelengths. The present invention, by contrast, is based on an eight pass resonant cavity and, for a given geometry, is sensitive to only a narrow band of wavelengths.
Liddiard (U.S. Pat. No. 4,574,263 March 1986) also provides a mirror to increase the sensitivity of the detector, but notes that said mirror is optional and not key to the invention (which it is in the present invention).
SUMMARY OF THE INVENTION
It has been an object of the present invention to provide a device that may be tailored to detect, with a very high level of sensitivity, any chosen narrow band of infrared radiation in the general wavelength range from 1 to 15 microns.
A further object of the present invention has been to provide a device that is able to detect, with a high level of sensitivity, a wide range of infrared wavelengths in the general wavelength range from 1 to 15 microns.
Yet another object of the present invention is to provide a device that is capable of detecting, simultaneously, radiation in any of several chosen narrow bands of infrared radiation in the general wavelength range from 1 to 15 microns.
Still another object of the present invention has been to provide an efficient method for manufacturing said devices.
These objects have been achieved by means of design that is based on an infrared analog of the Fabry Perot interferometer, using one curved, fully reflecting, plate and one planar, mainly reflecting, but partially transmitting, plate. The space between these plates behaves as a resonant cavity which can be built to respond to either a broad or a narrow band of wavelengths in the general range between 1 and 15 microns. It is also possible to combine several detectors of different narrow bands in a single device. Actual detection of the radiation is based on use of thin film resistors, having a high thermal coefficient of resistance, that are thermally isolated from the other parts of the structure. Manufacture of the devices has been achieved through application of a variety of techniques commonly in use for micro-machining.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a classical Fabry Perot interferometer.
FIG. 2 shows a modification of the Fabry Perot interferometer that uses curved rather than planar plates,
FIG. 3a shows the basic elements that comprise the present invention.
FIG. 3b is a plan view of part of FIG. 3a.
FIGS. 4 and 5 show the distribution of radiation inside the resonant cavity of the present invention.
FIG. 6 shows an embodiment of the present invention that can be tailored to respond to radiation in only a narrow band.
FIG. 7 shows an embodiment of the present invention that can be tailored to respond to radiation over a wide range of wavelengths.
FIG. 8 shows an embodiment of the present invention that can be tailored to detect radiation in several narrow wavelength bands simulataneously.
FIGS. 9-13 illustrate the various steps that are followed in the manufacture of the embodiment shown in FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3a shows two silicon plates 31 and 32. They may be separated by anything from about 10 to about 100 microns. Silicon is the material of choice since it is transparent to infrared radiation over the wavelength range 1-15 microns, with little or no variation in refractive index. Top plate 32 has a planar upper surface. Its lower surface is also initially planar but a concave depression, concavity 34, having a radius of curvature between about 15 and 50 microns, has been formed in its surface.
Bottom silicon plate 31 has two surfaces, the upper one being optically flat while the lower surface has a roughness value between about 10 to 50 microns. This roughness is needed to eliminate the possibility of resonant cavities being formed between the top and bottom surfaces of 31 and/or the bottom surfaces of 31 and 32. The thickness of the plates may range from about 0.2 to 0.5 mm., with 0.45 mm. being typical. The lower surface of top plate 32, including the concavity, is coated with a layer of metal 33 such as aluminum to a thickness between about 0.5 and 1.3 microns, 1 micron being typical, sufficient to make surface 33 essentially totally reflective of infrared in the 1-15 micron range. The upper surface of plate 31 is coated with layer 35 of a metal such as tungsten, molybdenum, or gold to a thickness between about 40 and 75 nanometers, 50 being typical, designed to give a reflectance of at least 99%, in the 1-15 micron range, with essentially no absorption.
A temperature sensitive device 36, typically a thin film resistor comprising chromium or titanium oxide, is permanently mounted a short distance above layer 35 and is thermally isolated from said plate. The method and structure used to accomplish this will be described later. Four spacers (not shown) are formed around detector 36. Plate 32 is then brought into contact with said spacers and sealed to them, forming a cavity (also not shown here) which is large enough to encompass concavity 34. Said cavity is then evacuated just prior to sealing.
The embodiment illustrated in FIG. 3 shows only a single infrared detector. It is possible to associate a plurality of detectors with a given concavity, such as 46 as illustrated in FIG. 4. Envelope 41 shows the envelope of confinement for the radiation within the cavity. Such multiple detectors may be electrically connected together so as to enhance the sensitivity of a given structure. However, as the radiation makes its eight passes within the confines of the cavity, the presence of material near the center of envelope 41 tends to cause premature dissipation of the beam's energy prior to the completion of all eight passes so, in an alternative embodiment of the invention, the detectors are confined to the outer edges of radiation envelope 41. This is illustrated in FIG. 5.
FIG. 6 shows an embodiment that has been optimized for fine wavelength tuning. Many detectors, such as 61, share a single resonant cavity (not shown) containing a single concavity 62. At the wavelength for which the device has been designed (and multiples thereof) trapped radiation, that originally entered at 65, will be accumulated to fall on the detectors, otherwise it will be spread out within the cavity.
The embodiment shown in FIG. 7 is intended to achieve higher spacial resolution by the image detector. Each of the detectors, such as 71, has its own concavity, such as 74, so the spatial resolution of this embodiment is much higher than that of the previous device shown in FIG. 6. It could thus be used as part of an array with each of the individual detectors serving as a single pixel measuring about 10 microns across.
FIG. 8 shows an embodiment which is, in effect, a merging of the embodiments shown in FIGS. 6 and 7. Top plate 81 includes three concavities, such as 82, each of which is associated with three detectors of its own, such as 84, which all share bottom plate 83. Two of the opposite spacers, 85 and 86, of the cavity 87 have intentionally been given different dimensions. For example, in one embodiment spacer 85 measured about 35 microns while spacer 86 measured about 37 microns. This caused plate 81 to lie at an angle (typically between about 1° and 4° of arc) relative to plate 83 so that the effective distance between the plates varied from about 40 microns at the center of concavity 88 to about 42 microns at the center of concavity 89. As a result, the three concavities were tuned for different wavelengths: concavity 88 for 14.54, 13.91, 13.33, etc. microns, concavity 82 for 14.90, 14.26, 13.66, etc. microns, and concavity 89 for 14.60, 14.00, 13.44, etc. microns. In general, the mean spacing between the non-parallel plates could be anything in the range of from about 15 to 50 microns. Such a design makes possible the analog of color imaging for infrared.
We will now describe the manufacturing process for the embodiment shown in cross-section in FIG. 8 in greater detail: To describe the preparation of the upper and lower silicon plates 81 and 83, it is convenient to refer once again to FIG. 3 where these plates are designated as 32 and 31 respectively.
A concavity is formed in the lower surface of top plate 32 by first forming a cylindrically shaped trench by means of electron bombardment and then isotropically etching said trench. The etchant acts more slowly where the circular and planar walls of the trench meet, the net result being to remove sharp corners and generate an approximately sherical concavity. The lower surface, including the concavity, is then coated with a layer of aluminum to a thickness between about 0.5 and 1.3 microns. This renders said lower surface fully reflective.
The preparation of bottom plate 31 begins by roughening its lower surface by means of sand blasting (or equivalent) to a roughness value between about 10 and 50 microns. Then a layer of thermal silicon oxide 30 is grown on the upper surface of the bottom plate. Layer 30 is then coated with layer 35 which comprises gold, molybdenum, or tungsten and has a thickness of about 50 nanometers. Layer 35 has a reflectance that is slightly less than 100%, while still having a small, but non-zero, transmittance. Layer 35 is then patterned and etched into approximately square areas that roughly correspond in size and location to concavities 34 in top plate 32.
Next, a second layer of silicon oxide 37 is deposited in a rectangular shape over the layer 35 areas by chemical vapor deposition to a thickness between about 1.8 and 2.5 microns. It is then itself patterned and etched into slightly larger areas than the concavities, symmetrically overlapping the layer 35 areas. The purpose of layer 37 is to serve as a sacrificial layer, as will be seen shortly.
This is followed by the deposition of silicon nitride layer 38 with a thickness of between about 2 and about 5 microns. After heating at around 1,000° C. for a few minutes, to achieve stress relief, a layer of resistive material 36, comprising chromium or titanium oxide, is deposited onto layer 38 and then patterned and etched to form a resistor having a typical serpentine shape. A layer of aluminum is then deposited, patterned, and etched to form wiring pads 101, which contact the ends of the resistors and connect them to external terminals.
The final layer to be deposited at this stage of the process is a second layer of silicon nitride 39 having a thickness between about 900 and 1,100 Angstrom units. Layer 39 covers the entire exposed surface and will serve both as a protective layer as well as to prevent shorting between wiring pads 101 by the metallic spacers (to be described below).
The two layers of silicon nitride 36 and 38 are now patterned and etched to form a support platform for the resistor as well as supportive legs for said platform. This can be seen in the plan view shown in FIG. 3b. FIG. 3a can be seen to be a jagged cross-section (3a-3a) taken through FIG. 3b. Sacrificial silicon oxide layer 37 is now selectively removed by etching in hydrofluoric acid. This releases the platform so that it becomes free-standing, thereby isolating it from thermal contact with all surfaces other than its own supportive legs.
This completes preparation of the top and bottom plates and lays the way for their assembly. This is shown in FIGS. 10 through 13. Assemblages of the type shown in FIG. 3 or FIG. 8 are, of course, located between the two plates but have been omitted from the diagrams for simplification purposes. Similarly, most of the wiring pads 101 have also been omitted except for a couple of examples in FIG. 10.
Support spacers, such as 91 in FIG. 9 are now formed, in pairs, on the top surface of bottom plate 83 as shown in FIG. 10. Said spacers comprise an alloy of nickel and iron and are electroformed in photoresist molds. The alloy typically comprises about 37% nickel and about 63% iron, being selected because it has a near-zero coefficient of thermal expansion. As seen in FIG. 11, a second pair of spacers 85 and 86 are now formed in a similar manner so that a four walled enclosure results. Note that two openings 110 and 111 have been left so that the enclosure can be evacuated.
With the enclosure in place, top plate 81 is carefully aligned with respect to plate 83 so that the centers of the concavities and the centers of the resistor bearing platforms line up, following which the two plates and the spacers are fused together, producing the structure shown in FIG. 12. This is then evacuated and, while still under vacuum, the openings in the enclosure (one of which, 121, is shown in FIG. 12) are sealed. Sealing may be accomplished using either epoxy resin or fired glass frit. The former is somewhat more convenient to use but does not lead to as good a final vacuum inside the enclosure as does the fired frit. The completed assembly now has the appearance shown in FIG. 13. Front wall 136 is original spacer 86 after opening 121 has been sealed.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention. | An infrared detector device is described. It is based on an infrared analog of the Fabry Perot interferometer, using one curved, fully reflecting, plate and one planar, mainly reflecting, but partially transmitting, plate. The space between these plates behaves as a resonant cavity which can be built to respond to either a broad or a narrow band of wavelengths in the general range between 1 and 15 microns. It is also possible to combine several detectors of different narrow bands in a single device. Actual detection of the radiation is based on use of thin film resistors, having a high thermal coefficient of resistance, that are thermally isolated from the other parts of the structure. Details relating to the manufacture of the devices are given. | 6 |
SUMMARY OF THE INVENTION
This invention relates to a device for forming contraction joints in wet concrete.
Contraction joints are formed in concrete to allow for controlled cracking of the concrete during curing. Conventional methods of forming joints include hand tooling, sawing, and mechanical inclusion. The methods are expensive, time consuming and sometimes inefficient.
The device of this invention teaches a novel method of forming a contraction joint in wet concrete. The device includes a quantity of ribbon which is fed through a housing channel part into the wet concrete at a selected depth. The ribbon forms a thin joint within the concrete, permitting proper cracking during curing. The method is fast, efficient, and highly economical.
Accordingly, it is an object of this invention to provide a novel device for forming contraction joints in concrete.
Another object of this invention is to provide a contraction joint installer which is efficient, rapid and economical.
Another object of this invention is to provide a novel method of forming contraction joints in concrete.
Other objects will become apparent upon a reading of the following descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the ribbon joint installer of this invention.
FIG. 2 is a side view showing the installer in use with a part of the cover and blade broken away for purposes of illustration.
FIG. 3 is an enlarged view of that portion of the installer shown within broken line circle 3.
FIG. 4 is a perspective view of the joint installer being supported in a towing pan.
FIG. 5 is a portion sectional view taken along line 5--5 of FIG. 4 showing the installer in use, and with portions of the pan shown in fragmented form.
FIG. 6 is a perspective view of the installer with the cover raised and portions of the housing cut away for purpose of illustration.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments herein described are not intended to be exhaustive or to limit the invention to the precise forms disclosed. They are chosen and described to best explain the principles of the invention and its application and practical use to thereby enable others skilled in the art to utilize the invention.
The contraction joint installer shown in the drawings is used to produce weakened plain joints in wet concrete. The joint installer 8 shown in FIGS. 1-2 is adapted to be pushed along the surface of wet concrete 12 to form the joint.
Installer 8 includes a metal base plate 14 and a depending central U-shaped flange portion 16 or blade. Flange portion 16 is formed to provide a rearwardly inclined longitudinal channel 18 or guide which extends from the upper face 15 of plate 14. Resting upon plate 14 is a housing 20 having a side wall 21 and a lower wall 22 which includes an upright post 24. Housing 20 is attached to plate 14 and includes a slit 26 in its lower wall 22 which is aligned with channel 18.
A mounting bracket 34 is attached to plate 14 at its upper face 15. A cover 36 is pivotally connected at 38 to bracket 34 and serves to enclose housing 20 by overlying its side wall 21 as shown in FIG. 1. Cover 36 includes a transparent window 40 which extends radially over post 24 and allows viewing of the contents inside housing 20 without lifting cover 36. An elongated handle 42 is connected at its lower end to mounting bracket 34 and extends upwardly and rearwardly from housing 20 to provide a means for manually propelling joint installer 8 across the surface of concrete 12.
A roll 27 of ribbon 28 is placed about post 24 within housing 20. The leading end of ribbon 28 extends through slit 26 in housing wall 22 and channel 18 where it protrudes through exit opening 30 of flange portion 16 at the rear of plate 14. Window 40 in cover 36 allows the user to observe the amount of ribbon remaining upon the roll 27.
Joint installer 8 is utilized as follows. With the leading end of ribbon 28 extending slightly from channel 18, the plate 14 is set upon the surface 13 of moist concrete 12 with flange portion 16 being inserted into the concrete. The user then pushes installer 8 by handle 42 across the concrete with flange portion 16 forming a furrow into which ribbon 28 is fed as it is pulled from roll 27, as seen in FIG. 2 The wet concrete closes about the inserted ribbon as installer 8 progresses across the floor to allow the ribbon to be pulled through installer flange portion 16. When the strike off is completed, the user or operator cuts the ribbon 28 adjacent exit opening 30 of the flange portion. The concrete can then be finished over if desired to cover the installed ribbon which forms a stress relief in the concrete.
Joint installer 8 may also be utilized with a tray such as pan 50, allowing the formation of longer joints. Pan 50 has a slotted opening 51 in its lower wall 53. Flange portion 16 carried by plate 14 extends through opening 51 to insure proper operation of the joint installer 8. Wing nuts 54 tightened upon screws 55, which extend through pan wall 53, serve to hold joint installer 8 firmly within pan 50.
To utilize installer 8 and attached pan 50, a tow rope 56 is connected to the pan. Pan 50 is placed upon concrete surface 13 with the leading end of ribbon 28 set as described before. The operator then pulls on tow rope 56, drawing the pan and installer towards himself to cause ribbon 28 to form the joint as mentioned previously for the embodiment of FIGS. 1-3.
Joint installer 8 includes a ribbon depth-setter 58 which takes the form of a feeler pivotally connected to flange portion 16 of the installer near the level of the plate at its exit opening 51. By varying the position of depth-setter 58, such as seen in dotted lines in FIG. 5, the operator can control the depth at which the ribbon exits plate channel 28 due to the feeler pusing the ribbon further below the surface 13 of the concrete. In this manner, the depth of the formed stress joint can be varied.
It is to be understood that the scope of the invention is not limited to the above description, but may be modified within the scope of the appended claims. | A manually operable device which is for forming contraction joints in wet concrete and which includes a quantity of ribbon held within an enclosed housing. The ribbon is fed through a channel part in the device housing and into the wet concrete. | 4 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] This project has been funded by the Maryland Procurement Office under Contract Number MDA904-99-G-0703/005.
CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention generally relates to a debugger for a multiprocessor system. More particularly, the invention relates to a debugger that uses a “tree” communication structure comprising communication nodes that aggregate messages from debugging a plurality of processes and provide aggregated, as well as unaggregated, messages, to a debugger user interface.
[0005] 2. Background of the Invention
[0006] A computer program comprises a set of instructions which are executed by a processor. A software designer writes the program to perform one or more functions. An error in the program (referred to as a “bug”) may cause the program to operate in an unpredictable and undesirable manner. Accordingly, a computer programmer must debug the program to help ensure that it is error free.
[0007] The process of debugging a computer program generally requires the ability to stop the execution of the program at desired points and then check the state of memory, processor registers, variables, and the like. Then, the program can continue to execute. To facilitate the debug process, debug tools (i.e., software) are available which permit a programmer to debug the software. Debug programs have numerous features such as the ability to set break points in program flow, single stepping through a program (i.e., executing one instruction at a time and then stopping), viewing the contents of memory and registers, and many other features useful to the debugging process.
[0008] The computer field has seen numerous advancements over the years. One significant advancement has been the development of multiprocessor computer systems (i.e., computer systems having more than one processor). Multiprocessor systems permit more than one instruction to be processed and executed at time. This is generally called “parallel processing.” The instructions being concurrently executed may be instructions from the same program or different programs.
[0009] Although debugging a computer program that runs on a single processor computer can, at times, be difficult enough, debugging a computer program that runs on multiprocessors concurrently adds considerable complexity. For example, the debugging process may require checking on and keeping track of the status of registers and memory associated with a multitude of processors in the system. Additional complications occur when debugging a multiprocessor system and those complications can best be understood with reference to FIG. 1.
[0010] [0010]FIG. 1 shows a conventional multiprocessor system comprising a plurality of application processes 10 (labeled as “Process 0,” “Process 1,” and so on). Each application process 10 comprises at least one processor and may include more than one processor. The debugging of application software that runs on the various processes 10 can be controlled and monitored via a debugger user interface 18 which has a separate communication channel 16 to/from a debug server 12 associated with each process. Through interface 18 a person can, for example, set break points, examine register contents, etc. As shown, each process 10 is associated with a debug server 12 which may be a computer program that actually causes the actions desired by the computer programmer to occur. The debug server 12 may be embedded in the associated process or be separate from the process. In general, the debug servers 12 cause the debugging actions to occur that the programmer feels are necessary to debug the application and provides status information and memory/register data back to the debugger user interface 18 .
[0011] The architecture shown in FIG. 1 works generally satisfactory for systems having relatively few processes. This is true for several reasons. First, many operating systems limit the number of communication channels 16 that can be open concurrently for a given process. Thus, the number of communication channels that can be open at a time pertaining to the debugger user interface 18 (which itself is a process) may be limited to a number that is less than the number of processes 10 in the system.
[0012] Timing can also become a problem for debuggers in the multiprocessor architecture shown in FIG. 1. It takes a finite amount of time to process a message from a debug server 12 . This amount of time is accumulated when considering processing responses from all of the debug servers 12 . For example, if it takes 1 millisecond for the interface 18 to process a message from one debug server 12 and the system includes 2000 processes, then it would take as much as 2 seconds (2000 milliseconds) to finish processing a message in response to a single command to the interface 18 . This delay can detrimentally interfere with the debugging process.
[0013] The problems described above become more severe as the number of processes increases. Accordingly, a solution to these problems is needed. Such a solution would permit a more efficient debug operation for multiprocessor systems.
BRIEF SUMMARY OF THE PREFERRED EMBODIMENTS OF THE INVENTION
[0014] The problems noted above are solved in large part by providing a computer system with an aggregator network that fans out commands and aggregates messages. A preferred embodiment of the computer system includes a plurality of processes on which an application executes, the aggregator network and a debugger user interface. Using the debugger user interface, commands can be created and sent through the aggregator network to debug servers associated with the processes. Further, messages from the debug servers are routed through the aggregator network to the debugger user interface. The aggregator network preferably, whenever possible, combines the debug servers' messages into fewer messages and provides a reduced number of messages to the debugger user interface.
[0015] The aggregated messages generally contain the same information as the messages they aggregate and identify the debug servers from which the messages originated. The aggregator network examines the debugger server messages for messages that have identical or similar data payloads. Messages with identical data payloads can be easily combined into a single message that indicates which debug servers generated the identical messages. Messages with non-identical payloads having some common data values can also be aggregated. A message that aggregates messages with similar, but not identical, payloads preferably identifies the identical portions of the payload and the non-identical portions along with an identification of the debug servers associate with the non-identical portions. Not all messages can necessarily be aggregated and such unaggregated messages are also routed from the processes through the aggregator network to the debugger user interface.
[0016] The debugger user interface can store and process the messages in their aggregated form or convert the aggregated messages to their unaggregated form. This feature is selectable via the debugger user interface.
[0017] This aggregation of processor message alleviates the burden on the debugger user interface which otherwise would have to be capable of receiving and processing many more messages. Further, the aggregator network is one preferred form of a multi-layer communication network that comprises a plurality of communication nodes that permit a plurality of processes to send messages to a single debugger user interface, and commands to be routed to the processes. Such a multi-layer communication network provides an architecture in which all processes have open and active communication channels despite reasonable limitations imposed by the operating system on the number of communication channels to/from an individual process. These and other advantages will become apparent upon reviewing the following disclosures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which:
[0019] [0019]FIG. 1 shows a conventional debug architecture in which a debugger user interface includes a separate communication channel to each process debug server in the system;
[0020] [0020]FIG. 2 shows a preferred embodiment of the invention in which a balanced aggregator network is used to couple debug servers associated with processes to a debugger interface;
[0021] [0021]FIG. 3 shows a method of aggregating messages having identical data payloads;
[0022] [0022]FIG. 4 shows a method of aggregating messages having non-identical data payloads;
[0023] [0023]FIGS. 5 a and 5 b show an alternative method of aggregating messages having non-identical data payloads;
[0024] [0024]FIG. 6 shows a method of aggregating messages provided from separate aggregators;
[0025] [0025]FIGS. 7 a - 7 c include tables of routing information associated with the aggregator network; and
[0026] [0026]FIG. 8 illustrates one embodiment of an unbalanced aggregator network.
NOTATION AND NOMENCLATURE
[0027] Certain terms are used throughout the following description and claims to refer to particular system components. As one skilled in the art will appreciate, computer companies may refer to a component and sub-components by different names. This document does not intend to distinguish between components that differ in name but not function. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. Also, the term “couple” or “couples” is intended to mean either a direct or indirect electrical connection. Thus, if a first device couples to a second device, that connection may be through a direct electrical connection, or through an indirect electrical connection via other devices and connections. In addition, no distinction is made between a “processor,” “microprocessor,” “microcontroller,” or “central processing unit” (“CPU”) for purposes of this disclosure. To the extent that any term is not specially defined in this specification, the intent is that the term is to be given its plain and ordinary meaning.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Referring now to FIG. 2, system 100 is shown constructed in accordance with a preferred embodiment of the invention. As shown, system 100 includes one or more application processes 102 coupled to a debugger user interface 114 via an aggregator network 110 . Although nine processes 102 (P 0 -P 8 ) are shown in FIG. 2, any number of processes can be debugged using the preferred embodiment. Each application process 102 to be debugged preferably includes, or is associated with, a debug server 104 which preferably is a commonly available piece of debug software, such as Ladebug provided by Compaq Computer Corporation, gdb provided from the Free Software Foundation, or dbx from Sun Microsystems, which can be used to set break points, check memory and registers, and other types of debugging tasks initiated via the debugger user interface 114 .
[0029] Using the debugger user interface 114 , a user (e.g., a computer programmer) can send debug commands to one or more of the debug servers and receive messages from the debug servers. The commands may be any commands useful to debugging an application that runs on one or more of the processes 102 . Examples of such commands may include commands that set break points in program flow, single stepping through a program, requests for the contents of memory and/or processor registers, and the like. The messages from the debug servers 102 to the user interface 114 may include the content of memory, the content of registers, status information, and other information that may be useful in the debugging process. The user interface 114 itself preferably runs on a process and includes at least one processor, an input device (e.g., a keyboard and mouse) and an output display device.
[0030] The aggregator network 110 preferably includes two features which help solve the problems noted above. One feature is that the aggregator network 110 preferably includes a hierarchy structure comprising one or more layers 116 and 118 and one or more aggregators 120 , 124 , 126 and 128 in each layer. The use of the aggregators to aggregate messages will be described below. For now, it should be understood that the salient feature of the aggregators is that they are one type of communication “node.” Each communication node (i.e., aggregator) receives and transmits messages and commands. Using the communication infrastructure shown in FIG. 2, no one process need have more communication channels than is permitted by any reasonable limitations on the system, such as the quantity of open communication channels which may be imposed by the operating system as explained above. As shown in FIG. 2, although there are nine processes 102 , each aggregator 120 - 128 only has four communication channels, one channel for each of four processes/aggregators. In the example of FIG. 2, aggregator 120 communicates with processes P 0 , P 1 and P 2 via communication channels 130 . Aggregator 124 communicates with processes P 3 -P 5 using communication channels 132 while aggregator 126 has communication channels 134 to processes P 6 -P 8 . Each aggregator in layer 116 also has a communication channel 136 to aggregator 128 in layer 118 .
[0031] Accordingly, aggregators 120 - 126 have three communication channels 130 , 132 , 134 to each of three processes and a fourth communication channel 136 to aggregator 128 . Aggregator 128 in layer 118 includes the three communication channels 136 to aggregators 120 , 124 and 126 and a fourth communication channel 138 to the debugger user interface 114 . Rather than having nine communication channels from the processes 102 directly to the debugger user interface, which would be the case with the conventional communication architecture of FIG. 1, the aggregator network 110 of FIG. 2 requires no more than four channels to any one process. The aggregator network 110 of FIG. 2 can be scaled for any number of processes. For example, additional aggregators could be added to layer 116 in the network 110 to communicate with hundreds or thousands of processes. Additionally, the number of communication layers in the aggregator network 110 could be increased beyond just the two shown in FIG. 2. Further still, aggregator 128 (layer 118 ) is not necessary to the implementation of a communication network which permits a plurality of processes to communicate with a debugger user interface 114 with the number of active communication channels that the operating system permits. Accordingly, aggregators 120 - 126 in layer 116 could simply communicate with the debugger user interface 114 without communicating through layer 118 . Broadly, the preferred embodiment of the invention includes at least one layer of communication nodes, each node communicates with one or more processes and to one or more other communication nodes or to a debugger user interface.
[0032] In addition to simply being communication nodes, the aggregators in FIG. 2 also perform another function. Accordingly, the second advantageous feature of the embodiment shown in FIG. 2 is that messages from debug servers 104 to the debugger user interface 114 are analyzed and, when appropriate, combined or otherwise aggregated together. For example, if each debug server 104 transmits the same message (e.g., the current date) ultimately destined for the debugger user interface 114 , rather than transmitting nine separate, yet identical, messages to the user interface 114 , the aggregator network 110 aggregates those messages preferably into a single message. The single message might include a single instance of the date and an indication that all nine processes 102 transmitted the date. There are numerous possible techniques to analyze and aggregate messages together and several such techniques will be discussed below. The message aggregation preferably occurs without regard to messages being sent from the debug servers 104 to the debugger user interface 114 . Messages communicated in the opposite direction (i.e., commands from the debugger user interface 114 to the debug servers) generally are not aggregated.
[0033] As shown in FIG. 2, each aggregator 120 - 128 in the aggregator network 110 analyzes and aggregates its input messages and forwards on an aggregated message to the entity to which it communicates. The aggregators in layer 116 aggregates messages from the debug servers 104 and the aggregator(s) in layer 118 aggregates messages from the layer 116 aggregators. Accordingly, aggregator 120 aggregates messages from the debug servers associated with processes P 0 -P 2 . Aggregator 124 aggregates messages from the debug servers associated with processes P 3 -P 5 while aggregator 126 aggregates messages from the debug servers associated with processes P 6 -P 8 . Aggregator 128 in layer 118 aggregates messages from aggregators 120 - 126 .
[0034] Whenever possible, each aggregator tries to aggregate its input messages together to forward on to the next entity in the communication chain. A plurality of messages may be aggregated into a single message or more than one message. In general, n messages are aggregated into m messages, where m is less than n. The value n is greater than 1 and, by way of example and without limitation, may be greater than 100 or greater than 1000.
[0035] Not all messages can be aggregated. Some input messages to an aggregator may be too dissimilar to be aggregated. Non-aggregated messages are simply forwarded on.
[0036] A message preferably includes header information containing routing specifics such as a destination address and a data payload. In accordance with a preferred embodiment, with regard to message aggregation, messages generally fall into one of the following three categories:
[0037] identical payloads
[0038] similar payloads
[0039] completely dissimilar payloads
[0040] Thus, two or more messages may have identical payloads, similar payloads or payloads too different to benefit from message aggregation. Message aggregation may occur for two or more messages that have identical or similar payloads. If the input message payloads into an aggregator are identical, the aggregator can use those input messages to generate a single output message with a single payload also identifying the processes 102 to which the aggregate message pertains. An example of aggregating messages with identical payloads is shown in FIG. 3. As shown, an aggregator receives two input messages 150 and 152 which have identical payloads 156 and 158 , respectively. The difference between messages 150 and 152 is that each originated from a different debug server. Message 150 originated from the debug server associated with process P 0 as indicated by numeral 0 in field 160 and message 152 originated from the debug server associated with process P 1 as indicated by field 162 . The aggregated message 154 preferably includes the same payload ( 156 , 158 ) as messages 150 and 152 . Field 164 includes a process identifier range which identifies the processes to which the aggregated message payload 156 , 158 pertains. In the example of FIG. 3, the value in field 164 comprises “0:1” indicating that the payload originated from the debug serves associated with processes P 0 and P 1 .
[0041] [0041]FIG. 4 illustrates the use of one suitable message aggregation technique for similar, but not identical, messages. As shown in FIG. 4, messages 170 and 172 are aggregated together by an aggregator to form aggregated message 174 . Message 170 originates from process P 0 as indicated by field 180 and message 172 originates from process P 1 as indicated by field 182 . Messages 170 , 172 have similar, but not identical, payloads 176 and 178 , respectively. Payload 176 in message 170 includes the date data value “Feb.11, 2002” and payload 178 in message 172 includes the date data value “Feb. 13, 2002”. The two date data values are identical except for the dates—11, 13. That is, portions 184 , 190 (“FEBRUARY”) are identical and portions 188 , 194 (“, 2002”) also are identical. That is, the initial portions 184 and 190 “FEBRUARY” (including the blank space immediately after the word FEBRUARY) in each payload and the ending portions 188 and 194 “, 2002” (including the blank space after the comma) are common to both message payloads. Portions 186 and 192 (values of 11 and 13, respectively) are different.
[0042] Aggregated message 174 can be formed as shown without repeating the common portions 184 , 188 , 190 , and 194 . Only the dissimilar portions 186 , 192 of the data payloads need to be individually identified. In the aggregated message 174 , field 196 identifies the processes (P 0 and P 1 in the example) from which the aggregated message originated. Data payload 198 includes three fields of data values which generally correspond to the three fields of each of the input messages 170 , 172 . Fields 200 and 204 relate the data values that are common to both input messages. These values are indicated as being common by not including any indication that those values are different in any way. Field 202 includes the data values from the input messages that are different between the messages. These values—11 and 13—are identified as a list of dissimilar data values by the use of predetermined syntax. Although any special syntax can be used, in the example of FIG. 4, the syntax includes brackets around the values and a semicolon indicating a range or a comma individually separating the values. Whether the aggregated messages use a semicolon to indicate a range or a comma to list the differences is a user-selectable feature. Thus, special syntax is used to encode or otherwise identify those data values of the input message payloads 176 , 178 that are unique; all other fields of the data payload 198 are assumed to contain data values that are identical to the aggregated messages.
[0043] [0043]FIG. 4, as shown, retains only the low and high values of the dissimilar fields, and does not retain the origins of the field values. This in itself can be useful to reduce processing and bookkeeping and to enhance speed. Alternate possibilities include retaining all the values and their origins, preferably in a compact form. This would allow a first presentation using a range as shown in FIG. 4, as well as being able to show more detail in expanded presentations. Aggregators could be in modes, e.g., based on time and space versus utility tradeoffs, to discard or retain various degrees of information. This disclosure covers all such cases.
[0044] In this way, messages that contain some identical and some non-identical elements of their data payloads can be aggregated into fewer messages, preferably a single message, that effectively provide the same information. FIGS. 3 and 4 illustrate one possible technique for aggregating messages, but numerous other techniques exist and are within the scope of this disclosure. For example, FIGS. 5 a and 5 b illustrate another technique. In FIG. 5 a , message 210 originated from process 0 and has a data payload comprising the value “ABCDEF”. Message 220 originated from process 1 and has a data payload comprising the value “BCDEFG”. In comparing the two payloads side by side there are no common elements to payloads. However, as shown in FIG. 5 b , if the data payload of message 220 is shifted by one character, or at least viewed in a shifted format, with respect to the payload of message 210 , then it can be seen that the two payloads include common data values. As shown, the values “BCDEF” 224 are common to both payloads, while the values A ( 226 ) and G ( 228 ) are unique to each message (A being unique to message 210 and G being unique to message 220 ). The aggregators preferably analyze the data payloads of their input messages to determine if identical alphanumeric strings, albeit in different portions with the payloads, exist in the input messages.
[0045] These messages can be aggregated together as shown by message 230 in FIG. 5 b . The payload comprising the aggregated message 230 indicates that the first value A ( 234 ) was an element of only the message from process P 0 (message 210 ). This fact is indicated by including the value A in brackets along with the process number to which that value pertains. Similarly, the ending value G ( 236 ) is encoded as being an element of a message from process P 1 only. The field 236 in aggregated message 230 contains the common data values, “BCDEF”. Again, as noted above, there are numerous ways to encode this type of information besides that shown in FIG. 5 b.
[0046] The example of FIG. 5 b assumes the values of the aggregated payloads are maintained in the same order. If, however, order is not necessary then the concept of FIG. 5 b can be extended to reorder payloads to permit aggregation.
[0047] The aggregation techniques described above generally pertain to messages being sent from processes 102 to the debugger user interface 114 (FIG. 2). Messages from the processes 102 are aggregated, if possible, by aggregators 120 - 126 in layer 116 . The aggregator 128 in layer 118 preferably aggregates the aggregated and non-aggregated messages from aggregators 120 - 126 on channels 136 . Aggregator 128 compares the messages it receives from the three aggregators 120 - 126 to determine if any of the messages received from different aggregators can further be aggregated. Also, aggregator 128 determines whether any non-aggregated input messages can be aggregated with either aggregated or non-aggregated messages from other aggregators. The aggregation techniques shown in FIGS. 3 and 4 can be used by aggregator 128 to aggregate messages received from different aggregators 120 - 126 in layer 116 .
[0048] [0048]FIG. 6 illustrates how a non-aggregated message received from one aggregator 120 - 126 can be compared to and aggregated with an aggregated message received from a different aggregator. In the example of FIG. 6, aggregator 128 receives two messages 240 and 154 . Message 240 originated from process P 6 and, according to FIG. 2, passed through aggregator 126 . Message 154 is an aggregated message that originated from processes P 0 and P 1 and was previously described in FIG. 3. Aggregator 128 compares the payloads of the two messages, determines that they are identical and aggregates the two messages together to form aggregated message 246 . Message 246 includes a process identifier field 238 which identifies all of the processes that provided messages that became aggregated together in message 246 . As such, identifier field 238 includes the values 0:1,6 to indicate that messages from processes P 0 , P 1 and P 6 are aggregated together by message 246 . The data payload 248 of message 246 is simply the payload from the messages generated by processes P 0 , P 1 and P 6 .
[0049] Further, it is conceivable to have aggregators operate on objects rather than text. Imagine a query of “statistics of age keyed by name.” The object would be a set. Each entry is a name and information about age statistics (e.g. n, sum(age), sum(age{circumflex over ( )}2) will allow count, average and standard deviation). “Aggregating” two objects would create a new object that represents the union of the names, but with the statistics entries combined, which in this case is a straightforward summation. This kind of partial aggregation can be done in the aggregator network/tree.
[0050] In fact, if the internal representation sorts the set by name, then aggregation can be done in a pipelined/flow-through fashion without having each aggregator read each full object from its inputs before doing the combination, and sending the large result out. Instead, knowing they are sorted allows an aggregator that sees, for example, “Robert” to know it will never see a “David”, so that if there are “David” s pending from other channels, it can safely combine and forward.
[0051] As described above, aggregators layer 116 aggregate messages from the processes 102 , while aggregator(s) in layer 118 aggregate messages from layer 116 aggregators. The message aggregation described herein pertains to messages being transmitted from the processes 102 to the debugger user interface. By aggregating messages whenever possible, fewer messages are provided to the user and the effort of debugging the application program is made considerably easier and more efficient.
[0052] Thus far, a balanced aggregator network has been shown. FIG. 8 shows one embodiment of an unbalanced network. As shown, aggregators 320 may receive inputs from debug servers, while aggregators 330 aggregate messages from other aggregators. The scope of this disclosure includes balanced and unbalanced networks. Further, there is no limit on the depth of the network (i.e., the number of levels in the network).
[0053] As noted above, commands or other information transmitted by the debugger user interface 114 to the processes 102 generally are not aggregated. Instead, each command is routed by the aggregators 120 - 128 to the appropriate destination location(s). Each command preferably is encoded with a process number (e.g., 0, 1, 2, etc.) or a process set corresponding to a group of processes as is commonly understood by those skilled in the art. Preferably, each aggregator has access to routing information which is used to determine how to forward commands on to other aggregators/processes. The routing information may take the form, for example, of a table which is loaded into memory. FIG. 7 a shows one exemplary embodiment of a routing table 300 which is useful for aggregator 128 . As shown, table 300 in FIG. 7 a lists the various processes, P 0 -P 8 , in the system along with an indication for each process of the layer 116 aggregator through which that process communicates. Accordingly, the routing information preferably states that aggregator 120 includes communication channels to processes P 0 -P 2 . Similarly, the routing information may state that aggregator 124 includes communication channels for processes P 3 -P 5 , while the routing information indicates that aggregator 126 includes communication channels for processes P 6 -P 8 . Aggregator 128 uses the routing information table 300 to determine to which aggregator 120 - 126 in layer 116 to transmit a command from the debugger user interface. It many cases, a command may need to be routed to processes corresponding to more than one aggregator 120 - 126 . In these cases aggregator 128 preferably broadcasts the command to all of the aggregators that are to receive the command.
[0054] The debugger user interface 114 similarly may have access to a table of routing information which informs the interface to which aggregator to route commands. FIG. 7 b shows one suitable embodiment of such a table 350 . Each entry in the table 350 includes a process set and a routing disposition. Because the exemplary embodiment of FIG. 2 shows the interface 114 only coupled to one aggregator (aggregator 128 ), table 350 includes only a single entry. Other entries could be included if the interface 114 coupled to other aggregators. Further, each of aggregators 120 , 124 , 126 also have access to a routing table. An exemplary table 370 is shown in FIG. 7 c for aggregator 124 .
[0055] The debugger user interface 114 will generally receive both aggregated and unaggregated messages from the processes 102 via the aggregator network. The messages can be dealt with in any desirable manner. For example, the messages can simply be logged to a file. Further, the messages can be viewed on a display (not shown) that is part of the debugger user interface 114 . If desired, and if sufficient information is available, aggregated messages can be converted back to their unaggregated form. This conversion process will essentially be the reciprocal process from that used to generate the aggregated messages in the first place. In general, the individual unaggregated messages can readily be recreated because each aggregated message identifies the processes from which the messages originated. Further, in the case of aggregated messages based on similar, but not identical, messages, such aggregated messages can be converted back to the original unaggregated messages if the aggregated messages retain the origins of the dissimilar payloads. Using this information, aggregated messages can be converted to their original unaggregated form.
[0056] The use of an aggregator network, such as the network described herein, advantageously solves or alleviates the problems discussed previously. First, the detrimental effects caused by the limitation as to the number of active communication channels that can be open at a time for any one process is avoided through the use of multiple, hierarchically-arranged aggregator processes in the aggregator network. Second, messages from the various processes can be aggregated within the tree, often concurrently with other aggregators, into preferably fewer messages to permit more efficient operation. The benefit of message aggregation increases as the number of processes in the system increases. The architecture is readily scalable to any number of processes (e.g., 100 or more or 1000 or more processes), and may provide significant advantages over conventional architectures (e.g., FIG. 1) when used in conjunction with 64 or more processes/debug servers.
[0057] The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. For example, the preferred aggregation technique described herein can be applied to messages that contain text, reply objects, or any other type of payload. It is intended that the following claims be interpreted to embrace all such variations and modifications. | A computer system includes an aggregator network that couples a plurality of processes on which an application executes to a debugger user interface. Using the debugger user interface, commands are created and sent through the aggregator network to the processes and messages from the processes are routed through the aggregator network to the debugger user interface. Whenever possible, the aggregator network combines the processors' messages into fewer messages and provides a reduced number of messages to the debugger user interface. The aggregated messages generally contain the same information as the messages they aggregate and identify the processes from which the messages originated. The aggregator network examines the processor messages for messages that have identical or similar data payloads and aggregates messages that have identical or similar payloads. | 6 |
This is a 371 national phase application of PCT/FR2007/051062 filed 4 Apr. 2007, claiming priority to French Patent Application No. FR 0651240 filed 6 Apr. 2006, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a drilling tool, particularly but not exclusively for making walls in the soil as obtained by mixing the cut soil with an additional binder.
BACKGROUND OF THE INVENTION
Soil mixing techniques whereby drilled ground is mixed in situ with a hydraulic binder are nowadays commonly used for improving substructures. The tools used generally employ special equipment resembling augers that are caused to rotate about a vertical axis. Those machines enable rectangular wall elements to be made by juxtaposing a plurality of augers, thereby requiring high-power machines to be used whenever the trench needs to reach depths greater than 10 meters (m).
A new type of machine has been in existence for several years that makes it possible to make rectangular foundation elements out of soil cement, i.e. by mixing a hydraulic binder with the soil that has been dug so as to make a portion of a trench, while also mixing the mixture. This operation is referred in the present patent application by the term “digging a trench while mixing cuttings with another material”.
Naturally, the mixture must be left in place in the trench that is being made so as to end up with a wall in the soil that results from the mixture of cut soil and hydraulic binder setting, which wall has its shape defined by the shape of the trench.
A machine of this type is described for example in patent applications US 2005/0000123 and US 2004/0234345.
That machine is constituted essentially by two pairs of cutters mounted on a support structure. Each pair of cutters is connected to a hydraulic motor. The motors are housed in a relatively bulky box located above the cutters.
When the motor is mounted in a bulky box, the drawback presented by the machine consists in the box in which the motors are housed presenting a relatively large apparent area. The presence of this box of large dimensions interferes considerably with raising the tool after it has performed the mixing, since the box needs to “barge through” the mixed material constituted by soil cuttings and hydraulic binder. In some circumstances, while the machine is being raised, the presence of this box can lead to the machine becoming blocked in the panel filled with the mixture constituted by the drilling cuttings and the hydraulic binder.
In the machine of that type, that is described in patent application US 2005/0229440, the two pairs of cutters are connected by a common transmission to a single motor that may be situated above the surface of the ground. The transmission is then complex and its efficiency mediocre.
Furthermore, since the two pairs of cutters are driven by the same motor, all of the cutters rotate at the same speed. Unfortunately, it can sometimes be advantageous to be able to give each pair of cutters a different speed of rotation, in particular to correct departures from the vertical while digging the trench. In addition, the power from the motor is shared between the two pairs of cutters providing operation is normal. However, if one pair of cutters becomes blocked, then all of the power from the motor must be absorbed by the other pair of cutters. That requires the system to be dimensioned mechanically so as to be able to accommodate this situation.
Excavator machines are also known for making trenches in the soil. Such machines are usually constituted by two pairs of rotary cutters mounted at the bottom end of a structure of large dimensions. The top end of the structure is secured to support means that are generally constituted by cables.
In horizontal section, the structure of the machine is generally rectangular in shape with dimensions substantially equal to the overall dimensions of the pairs of cutters. Thus, the dimensions of the right section of the structure are substantially equal to the dimensions of the horizontal section of the portion of trench that the machine can dig as it moves downwards.
Thus, the walls of the structure are substantially in contact with the walls of the portion of trench being dug, thereby ensuring that the machine is guided vertically in order to obtain a portion of trench that is likewise substantially vertical.
In addition, the soil cut by the cutters is removed via a suction tube having its inlet disposed between the walls of the cutters beneath the structure.
It is clear that such an excavator machine is totally incapable of mixing the cut soil with the hydraulic binder, so that the mixture is left in place in the portion of trench being dug in order to make the wall in the soil.
Documents EP 0 262 050 and GB 1 430 617 describe such a machine.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a drilling tool of this type that avoids the two above-mentioned drawbacks.
To achieve this object, the invention provides a drilling tool that comprises:
two pairs of rotary drums in axial alignment on parallel axes, each drum being fitted with a cutter; motor means for driving rotation of said drums; support means; and a support structure on which said drums are mounted to rotate and serving to connect said drums to the support means;
said tool being characterized in that:
said motor means are mounted inside the drums; and said support structure comprises:
a plate that is substantially orthogonal to the axes of rotation of the drums, the bottom ends of said plate forming bearings for said drums, said plate having constant thickness that is very small relative to the length of the axes of rotation of a pair of cutters; and a mounting pad connected directly to the bottom end of said support means and fastened to the top end of the plate, the top edge face of the plate connecting said pad to the bearing-forming means having a special shape so that, in association with the small thickness of the plate, it is significantly easier to raise the tool when it is being used for digging a trench while mixing cuttings with another material.
It will be understood, that since the motors driving the cutters are disposed inside the cutters, the tool does not have a box containing the motor or bulky transmission systems. Furthermore, each motor can be controlled independently to give each pair of cutters a different speed of rotation. Since there is no box above the cutters of the tool, it can be understood that raising the tool through the mixture of drilling cuttings and hydraulic binder is made considerably easier. This is made easier still by the particular shape of the support structure having only an edge that is in a position to oppose the drilling tool being raised, and this edge has dimensions that are small and a shape that is appropriate.
Preferably, the motors are hydraulic motors and the tool further includes sets of pipes for powering said motors, which pipes are constituted by holes in the thickness of the plate of the support structure. Thus, these power pipes are located entirely within the plate and cannot oppose the tool being raised after the trench has been dug and the drilling cuttings mixed with the hydraulic binder.
Also preferably, the top edge face of the plate of the support means is chamfered. This further facilitates raising the drilling tool through the mixture of drilling cuttings and hydraulic binder.
Also preferably, the support means comprise at least one guide portion having its bottom end secured directly to the pad of the support structure.
Also preferably, the dimensions of the pad, which extends horizontally, are substantially equal to those of the right section of the guide beam.
Thus, while the tool is being raised through the trench filled with the mixture of cuttings and hydraulic binder, the pad lies in line with the guide portion and therefore does not oppose this upward movement.
Also preferably, the thickness of the guide beam in the direction of the axes of rotation of the cutters is less that half the length of the axis of rotation of a pair of cutters, and the width of the section of the guide beam is less than one-third the overall size of the two pairs of cutters in the horizontal direction perpendicular to said axis of rotation.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the invention appear better on reading the following description of embodiments of the invention given by way of non-limiting example. The description refers to the accompanying figures, in which:
FIG. 1 is an elevation view of a drilling installation using the drilling tool of the invention;
FIG. 2 is a perspective view of the drilling tool with its guide bar;
FIG. 3 is an elevation view of the drilling tool assembly;
FIG. 4 is a partially phantom plan view of the drilling tool; and
FIG. 5 is a perspective view of the support means for the cutters of the drilling tool.
DETAILED DESCRIPTION
FIG. 1 shows a drilling machine using the drilling tool in accordance with the invention. The tool 12 is guided in the trench by a guide beam 14 of constant profile and preferably of rectangular right section. The tool 12 is fastened to the bottom end 14 a of the beam. The guide beam 14 serves to transmit thrust forces and traction forces to the tool 12 . It also serves to protect the pipes feeding the tool with hydraulic binder, together with the pipes powering the motors that drive rotation of the cutters. The guide beam 14 is connected by guide and drive means 16 , 18 to a vertical mast 20 . The mast is supported by a tracked vehicle 22 having installed thereon a system 24 for generating hydraulic power.
It will be understood that by causing the guide beam 14 to move upwards and downwards, the tool 12 is caused to move vertically in the soil so as to make a panel of a trench by drilling the soil and mixing the drilling cuttings with the hydraulic binder.
FIG. 2 shows the guide beam 14 with the drilling tool proper 12 secured to its bottom end 14 a . The drilling tool is constituted by two pairs of cutters 26 & 28 and 30 & 32 , with the cutters in a given pair being on a common axis and with the axes of rotation of the cutters being parallel and substantially horizontal in use. As explained below, according to an essential characteristic of the invention, the motors for driving rotation of the cutters 26 to 32 are disposed inside the cutters themselves, thereby avoiding any need to provide an external motor for driving the cutters.
More precisely, the pairs of cutters 26 to 32 are connected to the bottom end 14 a of the guide bar by a support structure given overall reference 34 . In a variant, the support structure 34 may be fitted with scraper systems 36 that serve, when the soil is sticky, to remove the soil that adheres to the cutters between their teeth 38 .
With reference now to FIG. 5 , there follows a description in greater detail of the support structure 34 of the tool. The support structure 34 is constituted firstly by a plate 40 that, in the particular embodiment described, consists of two half-plates 42 and 44 interconnected by a triangular part 46 connecting the two half-plates 42 and 44 to a mounting pad 48 used for securing the support structure 34 to the bottom end 14 a of the guide beam. The pad 48 is naturally substantially horizontal and thus orthogonal relative to the half-plates 42 and 44 . As shown in the figures, the mounting pad has substantially the same dimensions as the horizontal right-section of the guide portion 14 . The bottom ends 44 a , 42 a of the half-plates are fitted on each of their faces with pairs of coaxial cylindrical bushings 50 , 52 and 54 , 56 . These bushings have axes X, X′ and Y, Y′ that are orthogonal to the two half-plates 42 and 44 and that serve firstly for mounting the hydraulic motors and secondly for guiding rotation of the drum on which the cutters proper are mounted.
As is well known, the guide bar 48 a , in horizontal right-section, is of dimensions that are very small compared with those of the drilling tool 12 and thus compared with those of the drilling performed by the tool.
More precisely, the depth l′ of the pad 48 (see FIG. 5 ) is less than half the length H of the axis of a pair of cutters 26 to 32 (see FIG. 4 ). The width l of the pad 48 (see FIG. 5 ) is less than one-third of the length L of the drilling tool 12 (see FIG. 4 ), where “length” designates its maximum dimension in a horizontal plane.
Preferably, the top edge face 44 b , 42 b of each half-plate presents a first portion 44 c , 42 c that is substantially horizontal and short in length followed by a downwardly-sloping portion 44 d , 42 d , thereby constituting the sides of a triangle of apex that would be disposed towards the pad 48 . Also preferably, the edge faces 42 b , 44 b of the half-plates 42 and 44 are chamfered, as can be seen more clearly in FIG. 4 .
More generally, the top edge face of the plate 40 is of a shape that makes it easier to raise the drilling tool through the mixture of cut soil and hydraulic binder that is contained in the trench.
As already mentioned, the motors for driving rotation of the cutters are preferably hydraulic motors. Under such circumstances, the power fluid feed pipes are constituted by holes such as 58 and 60 made in the thickness of the half-plates 42 and 44 . The top ends of the pipes 58 , 60 open out into orifices such as 62 that are formed in the pad 48 for connecting the pipes 58 and 60 to the power fluid feed pipes that are located in the guide bar 14 .
Under some circumstances, when the soil is sticky, scraper systems 36 are fastened on either side of the central triangular part 46 of the support means 34 . These scraper systems 36 comprise scrapers such as 64 that are interleaved between the rows of teeth 38 , 38 ′, 38 ″ of the cutters so as to remove the soil that might adhere to the cutters between these teeth.
It should be observed that the scraper systems 36 present a profile that makes it easier to raise the drilling tool through the mixture of drilling cuttings and hydraulic binder.
FIG. 4 shows the cutters 30 to 36 mounted on the bushings 50 to 56 . Firstly there can be seen the hydraulic motors such as 70 , which motors are fastened within the bushings 50 to 56 . The outlet shafts from the motors 70 are connected mechanically in rotation and in translation to drums such as 72 having the cutters 30 to 36 together with their teeth 38 , 38 ′, and 38 ″ mounted thereon. The ends of the hydraulic fluid feed pipes 58 and 60 are connected by any suitable means to the system for feeding power to the hydraulic motors 70 .
It will be understood that when it is desirable to raise a drilling tool that is in a trench that is filled with a mixture of drilling cuttings and hydraulic binder, the only portions of the tool that oppose this upward movement are those constituted by the support plate 40 and possibly by the scraper systems 36 . The pad 48 is located in line with the guide bar 14 and therefore does not constitute an obstacle to raising the drilling tool.
The half-plates 42 and 44 are of small thickness and they have top edges 44 b , 42 b of profile that facilitates raising the tool, as explained above.
In a particular embodiment, the drilling tool presents a width H in the direction of the axes of rotation X, X′ and Y, Y′ that is equal to 800 millimeters (mm) and a length L in the direction orthogonal to these axes of 2800 mm.
If consideration is now given to the support plate 40 , its long dimension is 2200 mm and its thickness e is equal to 60 mm. Furthermore, the fastener plate 48 is rectangular in shape with sides having dimensions of 600 mm and 300 mm. It will be understood that during upward movement, the fastener plate 48 does not constitute an obstacle to such movement since it is in line with the guide bar 14 . Consequently, a length of only 1600 mm of the support plate 40 needs to be taken into consideration. Thus, the area opposing upward movement is 1600 mm×60 mm=96,000 square millimeters (mm 2 ). This section should be compared with the horizontal projection of the tool assembly, which projection presents an area equal to 2800 mm×800 mm, which is more than 2 million mm 2 . The area opposing upward movement is thus less than 5% of the area of the tool. During upward movement, the cutters are caused to rotate and therefore do not oppose such movement. When a cutting tool is fitted with pairs of cutters having axes that present a width of 500 mm, this ratio is slightly less than 10%. In general, the ratio between the areas is preferably less than 10%.
More generally, and preferably, the thickness e of the support plate 40 is less than 15% of the width H of the tool in the direction of the axes of rotation X, X′ and Y, Y′. More preferably, the ratio is no greater than 10%. This value for the ratio depends on the dimensions of the cutters. The larger the cutters, the smaller the ratio can be made. The means forming the plate 40 have a minimum thickness of 50 mm to 60 mm in order to ensure the plate presents sufficient strength and in order to make it possible to provide internal ducts therein for powering the motors. | The invention relates to a drilling tool comprising: two pairs of rotary drums in axial alignment on parallel axes; a motor mechanism for driving rotation of the drums; a support element; and a support structure on which the drums are mounted to rotate and serving to connect the drums to the support element; the tool being characterized in that the motor mechanism is mounted inside the drums and in that the support structure comprises a plate forming bearings at its bottom ends for the drums; and a mounting pad for fastening to the support element. | 4 |
BACKGROUND OF THE INVENTION
The present invention generally pertains to battery testers, and more particularly, relates to on-label thermochromic battery testers.
Batteries are often stored before being used. Batteries are typically stored by retailers before being sold. After purchase by a consumer, such batteries are again typically stored for some period of time prior to use. If the period of storage is significant, batteries may self-discharge. Therefore, it is desirable to utilize a battery tester to determine if a battery has sufficient charge to operate a desired device.
It is also desirable, on frequent occasions, to determine the remaining life of batteries which are in use. Many "good" batteries are discarded simply because the user cannot recall how long they have been used in a particular device, i.e., a camera, tape deck, etc. For similar reasons, batteries often reach a useless or near useless state of discharge when no replacements are readily available. Separate or stand-alone battery testers are known which indicate remaining battery power. However, such testers are easily misplaced and cumbersome to use.
Battery testers have been described that are included in a label secured to a battery. One type of on-label battery tester is known as a "thermochromic battery tester." Thermochromic battery testers typically include a conductive element that is selectively connected between opposite terminals of the battery. The conductive element includes a switch pad at one or both ends that is pressed by the user to connect the conductive element across the terminals of the battery. When the conductive element is connected between the battery terminals, it generates heat as a function of its resistivity and the current flowing from the battery. The level of current produced by the battery is one indicator of remaining battery capacity. Thermochromic testers further include a thermochromic layer, which changes its color or visual appearance as a function of the heat generated by the conductive element. By changing the visual appearance of the thermochromic layer, a thermochromic on-label battery tester may provide an indication of the discharge level of the battery. For example, a thermochromic material that changes between opaque and transparent states may be utilized to expose indicia underlying the thermochromic layer indicating that the battery is still "good" when a sufficient level of current is output from the battery.
To produce such thermochromic battery testers in the simplest manner and at the lowest cost, the conductive heating element is printed at a single printing station using a single conductive ink material. A suitable material that may be readily printed on a substrate and that exhibits suitable heat-generating properties in response to the current from the battery, is silver ink. The silver ink is typically printed so that the resistivity of the ink film is the same in all portions of the circuit. Although the thermal flux can be focused by making the circuit narrower and the resistance higher where a high flux is required, the entire circuit acts as a heater. As a result, a low resistance circuit which draws high current is required to produce sufficient thermal flux in the display section. Because silver ink is relatively expensive, the conductive heating element thus constitutes a significant portion of the total cost of providing a battery tester on a battery label.
Another problem associated with conventional thermochromic on-label battery testers is that the contact switches that a user is required to press to activate the tester may become relatively hot due to the high current levels flowing through the conductive element. Although the heat generated at the switch contacts is not hot enough to burn the user's fingers, this heat nevertheless may create an unpleasant sensation for the user.
SUMMARY OF THE INVENTION
Accordingly, one aspect of the present invention is to solve the above problems by providing an on-label thermochromic battery tester that is lower in cost and that has reduced levels of heat generated at the switch contacts. To achieve these and other aspects and advantages, the battery tester of the present invention comprises a heating element having a display portion and first and second connecting portions on either side of the display portion that have a lower resistivity than the display portion. The lower resistivity of the connecting portions may be achieved by using a different material than that used for the display portion or using the same material for both the display and the connecting portions but changing a property in the layers that results in a lower resistivity for the connecting portions. For example, the thickness of the display portion layer may be reduced relative to the connecting portions or a binder fraction may be higher for the display portion than for the connecting portion.
The features and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the written description and claims hereof, as well as the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an illustration of a battery having a battery tester label in accordance with this invention disposed about the outer periphery of the battery;
FIG. 2 is a cross section of the battery tester label taken along plane II--II of FIG. 1;
FIG. 3 is an exploded view of a subcomponent of the battery tester label, referred to herein as the tester device;
FIG. 4 is a top plan view of the inserted tester device;
FIG. 5 is a bottom plan view of the inserted tester device, the cross-hatching indicating a layer of adhesive;
FIG. 6 is an exploded view of another subcomponent of the battery tester label, referred to herein as the base layer;
FIG. 7 is a cross section of a battery and the battery tester label;
FIG. 8 is an exploded view of the battery tester label;
FIG. 9 is an exploded view of a plurality of battery tester labels disposed on a common releasable liner;
FIG. 10 is a top view of a conductive circuit constructed in accordance with a second embodiment of the present invention; and
FIG. 11 is a partial cross section of a variation of the conductive circuit of the present invention taken along plane XI--XI of FIG. 10.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates a battery and label assembly 1 comprising a battery can 2, a negative terminal 4, and a positive terminal 6. Can 2 may be in electrical contact with positive terminal 6. Battery 1 may include one or more electrochemical cells, which may be primary or secondary cells. Extending around and attached to the periphery of can 2 is a label 10 including a battery tester device 15, which is the subject of this invention. As shown, tester device 15 comprises switches 64 and 65 which activate tester 15 to indicate the state of charge of the battery by exposing indicia 23 or producing some other visual indication.
As illustrated in FIGS. 2-5, tester device 15 generally comprises a laminate or layered assembly having a substrate layer 20, an elongated electrically conductive circuit 18 disposed on a first face of substrate 20, and a pressure-sensitive adhesive 16 disposed on portions of both conductive circuit 18 and the first face of substrate 20. Adhesive 16, indicated by cross-hatching in FIG. 5, is preferably applied over conductive layer 18 in the pattern illustrated. Adhesive 16 is omitted from those areas which will overlie printed insulation 44 and switch pads 42 (FIGS. 6 and 8) when tester 15 is affixed to a base laminate 30. This adhesive pattern retards moisture from migrating to switch segments 60 and 61 of conductive circuit 18 while not interfering with the function of either the switches or the insulation discussed below.
Tester device 15 further comprises one or more graphic layers 22, preferably of decorative ink, and indicia 23 that are disposed on a second face of substrate 20 opposite the face containing conductive circuit 18. Tester device 15 also comprises a layer of a temperature-sensitive (i.e., thermochromic) indicating material 24 that is deposited upon the second face of substrate 20, preferably upon graphic layers 22 and indicia 23. A layer of a clear protective coating (not shown) is preferably deposited over indicator layer 24 and optionally upon graphic layers 22 and other exposed regions of the second face of substrate 20.
Conductive circuit 18 preferably has a central display portion 62 provided between two lower resistivity portions 82 and 84. The low resistivity portions 82 and 84 include switch segments 60 and 61. By forming switch segments 60 and 61 in a portion of conductive circuit 18 having a lower resistivity, the amount of heat generated at the contact switches 64 and 65 is substantially reduced. Conductive circuit 18 may be made of a single material such as a highly-conductive silver ink layer. To obtain different resistivities in portions 62, 82, and 84, the thickness of the layer forming portion 62 may be relatively thinner than that of connecting portions 82 and 84 or the binder fraction in the ink may be increased for portion 62.
An alternative method for obtaining different resistivities in the portions of conductive circuit 18 is to utilize different materials for these portions. For example, if connecting portions 82 and 84 are formed using a silver ink, central display portion 62 may be formed using materials of higher resistance such as carbon, nickel, silver-plated copper, or combinations of these materials.
The ratio of resistivities of display portion 62 to connecting portions 82 and 84 is preferably about 10:1, with the resistivity of display portion 62 being within the range of 100 mΩ/cm 2 to 10Ω/cm 2 and the resistivity of connecting portions 82 and 84 being within the range of 10 to 200 mΩ/cm 2 . It will be appreciated, however, that the present invention may be practiced using resistivities outside these preferred ranges and at ratios different from the preferred ratio identified above. Moreover, the preferred values listed above are those for a 1.5 V cell. Different values may be desirable for different cell constructions and types.
FIG. 10 shows a conductive circuit 118 having a pattern according to a second embodiment of the invention. As shown, connecting portions 182 and 184 include narrower sections 183 and 185 that connect between display portion 162 and switch segments 160 and 161, respectively. Like the first embodiment, the resistivity of connecting portions 182 and 184 is lower than that of display portion 162. This difference in resistivity may be accomplished by making the connecting portions thinner than the display portion (as shown in FIG. 11) or by making these portions of different materials.
By using less-expensive materials, such as copper, in place of the silver ink that is commonly used, and/or by narrowing the width of silver connecting portions 82 and 84 (182 and 184), the cost of conductive circuit 18 may be significantly reduced particularly when the tester circuit is configured to extend the entire length of the battery.
The tester device 15, as shown in FIGS. 2-5 and 8, is preferably prepared as follows. A plastic film is provided for substrate 20. Although FIG. 3 illustrates substrate 20 as being transparent, substrate 20 could be formed from a wide variety of other materials including opaque and translucent materials. Conductive circuit 18 is deposited on one face of substrate 20. Conductive circuit 18 is preferably deposited in the form of a pattern comprising two distal regions for forming switches, referred to and illustrated herein as switch segments 60 and 61, and a medially disposed area 62 which undergoes an increase in temperature upon passage of electrical current. The pressure-sensitive adhesive material 16 is deposited on at least portions of either or both conductive circuit 18 and a face of substrate 20. As previously noted, particular regions of conductive circuit 18 are left exposed and not covered with pressure-sensitive adhesive 16; namely, the switch segments 60 and 61 and area of controlled resistivity 62. A silicone-coated release liner, such as a silicone-coated paper or plastic film (not shown), is applied onto the previously deposited pressure-sensitive adhesive 16 to facilitate handling and/or storage of tester device 15.
Graphics and/or other labeling colors 22 in the form of a layer or layers of decorative ink and indicia 23 are printed onto the opposite side of substrate 20 from that on which the conductive circuit 18 is positioned. It is preferred that indicia 23 be disposed directly above the area of controlled resistivity 62 of conductive circuit 18 located on the other side of substrate 20. Additional graphics are also preferably printed to designate switch regions 64 and 65. If necessary, one or more curing operations may be performed to cure or partially cure the graphic or coloring layers.
On the same side of the substrate as the graphics and/or labeling colors, a thermochromic ink or other indicator material 24 is deposited onto substrate 20 such that it is situated directly above the area of controlled resistivity 62 of conductive circuit 18 and preferably over indicia 23. A clear protective coatings such as a varnish film, is then applied over and onto the indicator material, and optionally over the remaining regions of this side of substrate 20 to protect such regions from damage by subsequent manufacturing or storage operations. Each of the previously described layers or elements preferably have a thickness of from about 0.00005 inch to about 0.005 inch. The tester device, if necessary, can be cut to an appropriate size.
The second subcomponent of the preferred embodiment label 10 is a base laminate 30. As illustrated in FIGS. 2 and 6, base laminate 30 is a laminate or layered structure comprising a substrate 34, with one face having a layer of pressure-sensitive adhesive 32 for subsequent contact with a battery, and another face having one or more layers as follows: a metallization layer 36; a primer and/or decorative layer 38; an electrical insulation layer 40; and a thermal insulation layer 44. Also residing proximate to the thermal insulation layer are one or more switch throw pads 42 described in greater detail below.
Base laminate 30 is preferably prepared as follows. A plastic film is provided for the base layer substrate 34. The pressure-sensitive adhesive material 32 is deposited upon the face of the base layer substrate 34 that will subsequently face and contact the battery can 2. A silicone release liner is applied on the pressure-sensitive adhesive to facilitate handling and other processing operations. On the opposite face of base layer substrate 34, one or more graphic or labeling color layers are deposited, for instance, by printing. Preferably, metallization layer 36 is utilized to provide a decorative reflective layer. If a metallization layer is deposited, it will in most instances be necessary to deposit a receptive coating or primer layer 38 onto those regions of metallization layer 36 upon which other decorative layers are to be deposited. Primer layer 38 may in itself be a decorative layer. It is also desirable to deposit a layer of electrical insulation 40 upon metallization layer 36 and/or primer layer 38 to prevent electrical contact, i.e., shorting, between layer 36 and the conductive circuit 18 of tester device 15 during assembly of label 10.
Thermal insulation 44 is positioned in an area of base layer substrate 34 that will be disposed beneath the indicator material 24 and the maximum resistance area 62 of conductive circuit 18 of the previously described tester device 15. This thermal insulation reduces heat transfer from the area of controlled resistivity 62 of conductive circuit 18 to the battery. If such heat transfer is not controlled and the battery is permitted to act as a heat sink, the change in temperature at indicator material 24 may be insufficient to provide an accurate indication of the battery state of charge.
Thermal insulation 44, as shown, preferably comprises a plurality of apertures 46a which, when assembled into the laminate structure of the preferred label 10, provide air pockets which further thermally insulate the conductive circuit 18 from the battery. Optionally, a larger region of air space or void may be formed to serve as insulation by depositing a suitable spacer material onto the base laminate 30. The preferred insulative pattern is a series of islands printed onto layer 30 in the manner shown in FIG. 1A of U.S. Pat. No. 5,389,458.
A switch throw pad 42 is also formed surrounding a switch aperture 46b. This raised pad provides spacing between switch segment 61 of the conductive circuit 18 and battery can 2, and significantly minimizes the occurrence of accidental switch closure. Raised switch throw pad 42 is preferably formed by depositing or printing a dielectric ink or other suitable material. A second switch pad 42 may be formed proximate a switch aperture 47 as shown in FIGS. 6 and 8. This pad has not been found necessary for proper functioning of the tester.
In all of the foregoing operations, one or more cure steps may be utilized when depositing or printing any of the previously described layers, particularly the decorative inks. Each of the previously described layers or elements preferably has a thickness from about 0.00005 inch to about 0.005 inch.
Switch apertures 46b and 47 are preferably formed in base laminate 30 after printing thermal insulation 44 and switch throw pad 42. Such apertures are preferably formed by suitable punching operations. Registry problems are minimized by printing what is to become switch pad 42 as a solid disk and thereafter punching aperture 46b centrally through this disk. Switch apertures are formed in the base laminate 30 so that when the previously described inserted tester device 15 is combined with base laminate 30, switch apertures 46b and 47 are located directly beneath the distal switch segments 60 and 61 of conductive circuit 18. The preferred geometry for such switch apertures is a notch 47 for the negative switch segment 64 and a circle 46b for the positive switch segment 65.
The switches utilized in the battery tester label are preferably membrane switches such that a switch segment 60 or 61 of conductive circuit 18 overlies apertures 46b and 47 in base laminate 30. Apertures 46b and 47 in base laminate 30 enable contact between conductive circuit 18 and either a battery terminal or can 2 on the other side of base laminate 30. Upon application of a force to a switch segment, such as by applying finger or thumb pressure at switch segments 64 or 65, a portion of the switch segment is pressed or deformed through the opening in base laminate 30 to contact the battery terminal or can 2. Upon release of the pressure, the portion of the switch segment resiliently "springs" away from and, thus, out of electrical contact with the battery terminal or can 2. This configuration is referred to herein as "switchably connected."
A significant advantage provided by the present invention battery tester label is the absence of electrically conductive layers or members to electrically connect and disconnect the tester, i.e., conductive circuit 18, to and from the battery. This is remarkable and of significant benefit particularly when manufacturing a battery tester label in large volumes and at a high rate. This advantage of eliminating otherwise necessary electrically conductive switching components is achieved in part by providing a first switch 64 which is disposed very near a battery terminal, such as negative terminal 4. Such close proximity eliminates the need for additional conductive elements to electrically connect an end of circuit 18 to the negative battery terminal. It is most preferred to fold or shrink the peripheral edge of label 10 over the battery end at which the negative terminal is disposed, as illustrated in FIG. 1.
The tester device 15 is combined with base laminate 30 as follows and as best shown in FIG. 8. The tester device is positioned onto or adjacent base laminate 30 so that switch segments 60 and 61 of conductive circuit 18 overlie switch apertures 46b and 47, respectively. Tester device 15 is oriented such that the layer of pressure-sensitive adhesive 16 (the release liner having been removed if previously applied) is facing base laminate 30. Upon application of sufficient pressure to tester device 15 and base laminate 30, the two assemblies are securely attached to each other via adhesive 16, and form the preferred battery tester label 10 of the present invention. Optionally, a clear laminating adhesive 52 is deposited upon the outward facing surface of the resulting tester label as illustrated in FIG. 2, and a clear film 54, such as polyvinyl chloride or polyester, is applied over the coating and the resulting assembly cured. A coating of adhesive 52 and film 54, when applied onto the tester label, provide protection for the tester device and components thereof. It is most preferred that the transparent protective layer resulting from adhesive coating 52 and film 54 is deposited upon the battery tester label prior to application of the tester label to a battery.
The resulting battery tester label 10 is appropriately die cut to the size of the battery desired. Upon removal of excess trimmed label, a plurality of individual tester labels are left remaining on the release liner previously applied to substrate 34 of base laminate 30. The liner and label array may then be cut into strips and wound into a roll and stored for subsequent application to batteries.
The substrate layer utilized for either or both the base layer substrate 34 and the tester device substrate 20 can be made of any desired dielectric polymer material. It is preferable to use a dielectric polymer material that will shrink when assembled on a battery. Generally, polyvinyl resins, polyolefin resins, polyester resins and the like would be suitable. Specific examples include polyvinyl chloride, polyethylene and polypropylene. It is contemplated that substrate 20 could also be formed from other dielectric materials besides plastics such as paper or other cellulose-based materials. The thickness of the substrate layers is not particularly limited, but is preferably in the range of from about 0.0005 to about 0.005 inch, and most preferably from about 0.001 to about 0.003 inch.
The previously described indicator layer 24 in the inserted tester device 15 comprises a thermally sensitive material for indicating the capacity of the battery. The preferred thermally sensitive materials change color in response to a temperature change, which change is readily viewable by a consumer. Thus, the consumer, based on the color change, can determine whether the battery is good or needs to be replaced. Examples of such thermally sensitive materials include liquid crystal materials and thermochromic inks. Examples of suitable liquid crystal materials are of the cholesteric type, such as cholesteryl oleate, cholesteryl chloride, cholesteryl caprylate and the like. The indicator material could change from colored to colorless, colorless to colored, or from one color to a second color. A tri-color material could also be used. The preferred battery tester 10 shown in FIGS. 1-8 utilizes an indicating material which changes from colored to colorless upon activation to reveal indicia 23 underneath the indicator material 24.
Indicating materials, such as thermochromic inks, can be used singly or in combination. For example, in one embodiment different layers of the indicating material are employed. The layers are activated at different temperatures or states and can be designed to change different colors at different temperatures. For example, the layer of indicating material activated at the highest temperature will preferably be the bottom layer, i.e., closest to the battery, and the outer layers are arranged in decreasing temperatures of activation with lowest temperature material in the outermost layer, and so, readily viewable at the exterior of the battery.
Either one or both switch segments 60 and 61 of conductive circuit 18 can be out of contact with the respective terminals of the battery so that the tester circuit is open. In one embodiment of the invention, one of the switch segment ends is permanently in electrical connection with one terminal of the battery, while the other switch segment end is positioned out of contact with the other battery terminal. By forcing the switch segment end into contact with the other battery terminal, the switch is closed and the tester circuit is completed to test the battery. The most preferred embodiment is to utilize a dual switch tester as shown in the accompanying drawings.
The labels useful in this invention can also comprise additional electrical and thermal insulative layers, printing layers, protective layers and the like. Suitable materials for use as the different layers are those typically used in battery labels and include plasticized or unplasticized polyvinyl chloride (UPVC), polyesters, metallic films, paper and the like. The tester label can be in the form of a shrinkable tube label in which a battery is encased.
The battery tester label of the present invention is preferably applied to a battery as follows. A previously assembled tester device 15, having its underside containing pressure-sensitive adhesive 16 exposed, is aligned with a previously formed base laminate 30 (disposed upon a releasable liner) such that the electrically conductive circuit 18 of the inserted tester device is positioned to contact the thermal insulation 44 of base laminate 30. Upon application of sufficient pressure, the respective layers are secured and joined to one another via pressure-sensitive adhesive 16 disposed on the mating surface of tester device 15. The resulting battery tester label 10 is then attached to the outer periphery of a battery can 2 by removing the liner of base laminate 30 to expose adhesive 32 on the underside of label 10 and contacting the underside of base laminate 30 to the battery can 2. FIG. 7 (not to scale) illustrates a typical cross section of the battery and label assembly 1. It is also possible to produce the tester label of the present invention and apply such to a battery without using preassembled tester device and/or base laminate subcomponents. In another embodiment, the battery and tester label assembly is formed by combining the tester device 15 and base laminate 30 as previously described. The resulting label is then itself stored, such as on a releasable liner in a wound roll, until needed.
The present invention also enables the production of multiple tester label assemblies. That is, a plurality of tester devices 15 can be aligned and mated with a plurality of base layer components, i.e., regions of thermal insulation, switch throw pads, and switch apertures, disposed upon and defined within a common base layer to form a plurality of battery tester labels 10. The resulting set of multiple label assemblies can then be stored for subsequent use, or separated into smaller groups of multiple label assemblies or into individual battery tester labels.
In the most preferred embodiment, a series of battery tester labels 10, as illustrated in FIG. 9, are formed on a common releasable liner 70 for subsequent application to batteries. In this most preferred process, an array of tester devices 15 is provided, each tester device formed as previously described and disposed upon a common releasable liner (not shown). A base laminate 30 is provided comprising a dielectric substrate 34, a liner 70 that is releasably secured to the underside of the substrate such as by previously noted pressure-sensitive adhesives, and a plurality of regions of thermal insulation 44 disposed on substrate 34. A plurality of apertures 46b and 47 are formed in the base layer through preprinted switch pad 42, in the case of aperture 46b. The arrays of base layers and tester devices are then slit into serial rolls. Upon removal of the releasable liner from the serial roll of tester devices, thereby exposing adhesive 16 on the underside of substrate 20, the tester devices 15 are oriented with base laminate 30 such that each conductive circuit (not shown) of the tester device roll faces a corresponding region of thermal insulation 44 of the base laminate 30, and so that the switch segments of each conductive circuit directly overlie a corresponding pair of apertures 46b and 47 formed in the base layer. The roll of tester devices is then affixed or otherwise secured to the base laminate, for instance by adhesive 16, to form a roll of battery tester labels 10 disposed on the common releasable liner 70 residing underneath the base laminate.
It is preferable to apply a layer of a transparent adhesive and clear film, such as 52 and 54 illustrated in FIG. 2, upon the exposed face of the array of tester devices 15. Upon sufficient curing, if necessary, the resulting coated assembly is die cut so that each individual battery tester label disposed on releasable liner 70 is correctly sized for the battery to receive the tester label. Die cutting is performed so that releasable liner 70 is not cut, so that the tester labels 10 remain on a common sheet to facilitate handling and storage. The excess trimmed label, referred to as the matrix, is then removed.
Although the tester circuit of the present invention has been described as being implemented in a battery label, it will be appreciated by those skilled in the art that the tester circuit may be provided on the battery packaging, on a separate tester strip, on the housing of a battery pack, or on a device that utilizes batteries.
The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and are not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the Doctrine of Equivalents. | The battery tester of the present invention includes a heating element for generating heat in response to current supplied from a battery, and an indicator provided in proximity to the heating element for providing a visual indication of the remaining capacity of the battery in response to the heat generated by the heating element. The heating element has a display portion and first and second connecting portions on either side of the display portion that are selectively coupled to opposite terminals of the battery. The connecting portions of the heating elements have a lower resistivity than the display portion thereby reducing the heat generated at the switch contacts that are pressed by the user to activate the tester. | 8 |
CROSS-REFERENCE TO RELATED PATENT APPLICATION
This application is related to a commonly assigned copending U.S. patent application Ser. No. 07/351,686, filed May 15, 1989, now U.S. Pat. No. 4,959,540 and entitled "Optical Clock System for Computers", by B. Fan et al.
FIELD OF THE INVENTION
This invention relates generally to optoelectronic devices and, in particular, to a high-speed, low-jitter toggle Flip-Flop (F/F) device coupled to an optical pulse source for converting an optical pulse into electrical signals.
BACKGROUND OF THE INVENTION
The electrical transmission of fast timing signals introduces timing skew problems resulting from the limited bandwidth associated with the transmission and reception of the electrical signals through conventional electrical cables and transmission lines. One especially deleterious effect of the limited bandwidth is a degradation of fast risetime pulses. As a result, a variation in pulse receiver sensitivity or threshold causes an uncertainty or jitter as to an actual time of the arrival of electrical pulse. If the electrical pulse is being employed as a timing signal in, for example, a high-speed data processing system the presence of pulse jitter is especially detrimental.
FIG. 1 illustrates a simplified diagram of a conventional toggle circuit constructed as a set-reset flip-flop (SR-F/F). The SR-F/F includes two transistors Q A and Q B interconnected in a cross-coupled manner as shown. Each transistor is further coupled to a source of operating power (V dd ) through an associated load resistance R A and R B . In operation an electrical pulse to INPUT A sets OUTPUT logically HIGH, while an electrical pulse to INPUT B resets the OUTPUT logically LOW. The complementary signal OUTPUT* is LOW when OUTPUT is HIGH and vice versa. One advantage of such a SR-F/F circuit is that the output is always in a known logical state, as is important in the clocking of a computer system. That is, the OUTPUT signal may be employed as a clocking signal for logic circuitry of a computer system.
However, as was previously stated the electrical transmission of fast timing signals introduces timing skew problems resulting from the limited bandwidth associated with the transmission and reception of the electrical signals through conventional electrical cables and transmission lines. That is, if the electrical pulse signals coupled to INPUT A and INPUT B are transmitted through conventional electrical signal transmission means there is a limitation on an upper useable frequency that can be provided to the SR-F/F before the degradation of output pulses and increased output jitter become unacceptable. A problem is created if this upper usable frequency is below a frequency at which it is desired to clock associated logic circuits.
One proposed solution to this problem involves transmitting the input pulses as an optical signal instead of an electrical signal. For example, due to the inherently much wider bandwidth of an optical fiber the transmission of a fast rise time optical pulse through the fiber occurs without significant signal degradation. However, a problem is created when it is required to convert the optical pulse into an electrical signal for interfacing to logic circuits such as the SR-F/F in that optoelectronic circuits generally include electrical switching circuitry coupled to an optical receiver. The receiver typically includes a photosensor followed by several gain stages with output of the gain stages being applied to the associated switching circuitry. A problem with this conventional arrangement relates to the propagation delay between a time light is incident upon the photosensor and a time at which the switching circuit responds by changing state. Another problem relates to temporal jitter resulting from uncertainty in the propagation delay produced by the gain stages proceeding the logic circuitry.
In U.S. Pat. No. 3,686,645, entitled "Charge Storage Flip-Flop" and issued Aug. 22, 1972, Brojdo teaches a semiconductor memory array using a pair of bipolar transistors arranged as a F/F wherein a base of each transistor is connected to a high impedance when a power supply voltage is removed. As the high impedance forces slow decay of charge stored in the transistors, the state of the F/F can be maintained by a pulsed power supply, thereby reducing the average power dissipation of the F/F. Using the photosensitive nature of the transistors, the memory can be written optically by photogenerating charge in the base of one of the transistors, thereby unbalancing the transistors. A laser is employed to address a hologram for providing a desired light pattern for illuminating the memory array. This device specifically uses the low speed nature of the high impedance circuits to integrate the optical signals being applied. Thus, although a F/F circuit configuration is used the application and nature of operation do not address the problem of converting optical pulses into fast rise-time, low jitter electrical logic signals.
In U.S. Pat. No. 4,023,887, entitled "Optical Communication, Switching and Control Apparatus and Systems and Modular Electro-optical Logic Circuits, and Applications thereof" and issued May 17, 1977, Speers discloses optical communication, switching and control apparatus and system, including modular electro-optical logic circuits An optical F--F depicted in FIGS. 38a and 38b and described at Col. 23, lines 3-53 has one optical input and one optical output, and functions basically an optical "repeater" amplifier. It is noted that Speers teaches a binary device wherein the output frequency is one half of the input frequency and individual pulse timing is not preserved. This device is not believed to be suitable for fast rise-time/fall-time, low jitter applications.
The following U.S. Patents are noted of being of general interest. U.S. Pat. No. 4,223,330, entitled "Solid-State Imaging Device", describes a solid-state image pickup device for use in a TV camera and the like. U.S. Pat. No. 4,295,058, entitled "Radiant Energy Activated Semiconductor Switch", describes various power switching circuits using a light sensor such as photodiode coupled to a gate of a depletion-mode FET. U.S. Pat. No. 4,390,790, entitled "Solid State Optically Coupled Electrical Power Switch", relates to optically isolated switching devices such as solid-state relays for power switching or analog switches for signal switching. U.S. Pat. No. 4,521,888, entitled "Semiconductor Device Integrating a Laser and a Transistor", teaches an integrated semiconductor device including a diode laser and a transistor for modulating the laser. U.S Pat. No. 4,739,306, entitled "Calibrated-Weight Balance and an Analog-to-Digital Converter in which the Balance is Employed", discloses a calibrated-weight balance for the construction of very-high-speed analog-to-digital converters (ADC). The circuit includes a multivibrator comprising cross-coupled FETs 15 and 16. However, this Patent does not disclose the provision of optical inputs for driving the multivibrator.
It is thus an object of the invention to provide an optoelectronic pulse converter for converting an optical pulse into an electrical pulse having a fast risetime and a minimum of timing uncertainty.
It is a further object of the invention to provide a timing generation circuit that provides for the transmission of optical pulses of ultrafast risetime through extremely high-bandwidth optical fibers and which further converts these optical pulses into an electrical timing signal having leading and trailing edges exhibiting minimal timing uncertainty.
It is one further object of the invention to provide clock generation circuitry for a high-speed, short cycle time data processor that employs the transmission of optical clock synchronization pulses of ultrafast risetime through extremely high-bandwidth optical fibers and which further converts these optical pulses into an electrical clock signal having a minimal pulse skew.
SUMMARY OF THE INVENTION
The foregoing problems are overcome and the objects of the invention are realized by a high speed clock generator integrated circuit for generating a periodic electrical signal. The circuit operates as a pulse converter and converts optical pulses to electrical pulses.
The pulse converter includes a set-reset flip/flop, or OPTOGLE, having a pair of cross-coupled switching devices such as transistors or logic gates. The converter operates by coupling pulses of optical radiation to each of the switching devices for causing the switching devices to alternately toggle between an on-state and an off-state. Optical inputting devices such as photodiodes or photoconductors, or the gates of FET transistors themselves, are integrally formed upon a common substrate with the switching devices for minimizing stray inductive and capacitive reactances to substantially eliminate temporal jitter in an electrical output signal. A pulsed laser source and a fiber optic or optical waveguide provide non-overlapping optical pulses to each of the switching devices.
In accordance with one embodiment each of the switching devices is a GaAs MESFET device having a gate terminal comprised of a substantially transparent layer of electrical conductor having an interdigitated geometry and an overlying anti-reflection (AR) coating.
In this embodiment the transistors are each constructed of a semiconductor material having a characteristic energy bandgap for absorbing the optical pulse and generate sufficient charge carriers therefrom to induce a current flow though the transistor. The semiconductor material may be comprised of Group III-V material, of silicon, of other Group IV materials such as germanium or of combinations of these materials.
BRIEF DESCRIPTION OF THE DRAWING
The above set forth and other features of the invention are made more apparent in the ensuing Detailed Description of the Invention when read in conjunction with the attached Drawing, wherein:
FIG. 1 is a schematic diagram of a conventional two-input, two-output toggle circuit implemented as set-reset F/F;
FIG. 2 is a schematic diagram of a toggle circuit also implemented as set-reset F/F but which includes first and second optical inputs for changing the state of the F/F;
FIG. 3 illustrates the illumination of an interdigitated gate of a GaAs MESFET with an optical input signal for changing the state of the set-reset F/F of which the MESFET is a part;
FIG. 4 is a block diagram illustrating experimental apparatus for coupling high speed optical pulses to the optical toggle circuit of the invention;
FIG. 5 illustrates graphically an output electrical pulse of the optical toggle circuit in response to an input optical pulse, the x-axis divisions each indicating 500 picoseconds (500×10 -12 sec.);
FIG. 6 illustrates graphically the OUTPUT signal changing state in response to the optical pulses applied to OPTICAL INPUTs A and B;
FIGS. 7a, 7b, 7c and 7d illustrate various methods for coupling optical pulses to inputs of the optical toggle circuit;
FIG. 8a is a schematic diagram of a toggle circuit implemented as a set-reset F/F and including integrated photodiodes for coupling first and the second optical inputs to associated switching transistors for changing the state of the F/F;
FIG. 8b is a schematic diagram of a toggle circuit implemented as a set-reset F/F and including integrated photoconductors for coupling first and the second optical inputs to associated switching transistors for changing the state of the F/F; and
FIG. 9 is a schematic diagram of a toggle circuit implemented as a set-reset F/F including integrated photodiodes for coupling the optical inputs and further incorporating cross-coupled NOR-gate function devices in place of cross-coupled switching transistors.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 2 there is shown a SR-F/F that operates in accordance with one embodiment of the invention. The SR-F/F is an optically-toggled device and is referred to herein as an OPTOGLE 10. OPTOGLE 10 is constructed in some respects in a similar manner to the circuit of FIG. 1. OPTOGLE 10 includes two transistors Q 1 and Q 2 having their respective gate terminals interconnected in a cross-coupled manner as shown. Each transistor further has a drain terminal coupled to a source of operating power (V dd ) through an associated load, such as a resistance R 1 and R 2 , and a source terminal coupled to a common potential. While the OPTOGLE 10 may be implemented in a wide variety of semiconductor device technologies, in a presently preferred embodiment of the invention the transistors are MESFET devices comprised of semiconductor material having a high electron mobility, such as GaAs.
By example, C. Baack et al. in a journal article entitled "GaAs M.E.S.F.E.T.: A High-Speed Optical Detector", Electron. Lett., 13, 193(1977) report a GaAs MESFET photoresponse of less than 75 picoseconds.
In accordance with one embodiment of the invention a region between the source and drain of each MESFET is illuminated with a light pulse of narrow pulsewidth to achieve a high frequency of operation. Preferably the source of the light is a laser source such as a mode-locked gas laser, a mode-locked solid-state laser, or a gain-switched semiconductor diode laser as disclosed in commonly assigned U.S. patent application Ser. No. 07/351,686, filed 5/15/89. Due to the nature of the optical input, the MESFETs have an equivalent fourth port that is highly isolated from the gate, drain and source terminals. This equivalent fourth port is shown schematically in FIG. 2 and is referred to as OPTICAL INPUT A and OPTICAL INPUT B.
If the incident photon energy is greater than the semiconductor bandgap, a large density of charge carriers is generated. These charge carriers produce fast electrical pulses between the drain and source terminals of the FET by means of photoconductivity. In that the optical pulsewidth is preferably much shorter than the charge carrier lifetime, this effect is transient. In general, a risetime of the photoconductive signal is approximately the same as a risetime of the optical pulse while the fall time of the photoconductive signal is a function of the charge carrier lifetime. The photoconductive gain, defined as the number of charge carriers crossing a sample per second divided by the number of photons absorbed per second, is approximately the ratio of optical pulse duration to the transit time of the charge. As a result a large gain may be realized. The light-induced electrical pulse controls the output state of the OPTOGLE 10 in substantially the same manner as the electrical inputs INPUT A and INPUT B, and may be used interchangeably if desired. It should be noted that both electrical and optical inhibit capability is implicit in the circuit in that toggle activity can be inhibited by the application of a long duration pulse, or level, through either the electrical or the optical inputs. In general the transistor gates serve several purposes including providing positive feedback during changes of state and also providing external electrical terminals.
As shown in FIG. 6 an optical pulse applied to OPTICAL INPUT A sets OUTPUT logically HIGH, while an optical pulse applied to OPTICAL INPUT B resets the OUTPUT logically LOW. As was stated, electrical pulses could be substituted for some of the optical pulses or could be used to inhibit the operation of the optical pulses. The optical pulses may be derived from separate sources or from a common source. If the latter approach is employed one of the pulses is passed through an optical delay device, such as longer path length optical fiber, so that the second pulse is temporally offset from the first pulse by a desired amount. The amount of temporal offset affects the output electrical signal duty cycle as shown.
One significant advantage of directly coupling the light pulse to the gates of the transistors of the OPTOGLE 10 is the resulting simplicity of the circuit. That is, the MESFET itself functions as a photosensor and, with no signal amplifying or conditioning stage(s) required as with conventional types of optoelectronic devices, the propagation delay and the temporal jitter is minimized. Thus, the OPTOGLE 10 significantly reduces pulse skew characteristics which are especially critical in data processing clock signal distribution.
The operation of the OPTOGLE 10 has been experimentally demonstrated with commercially available GaAs digital integrated circuits constructed with depletion-mode MESFETs. FIG. 3 illustrates an enlarged view of a portion of an interdigitated MESFET. In this device the gate electrode 12a is disposed between the source electrode 12b and the drain electrode 12c. An illuminating laser beam spot 14 has a diameter of approximately 30 microns. The interdigitated geometry of the gate electrode 12a beneficially reduces shadow effects of the electrodes, thus improving light coupling, while also providing for a low interelectrode capacitance. The provision of an anti-reflection (AR)-coating 18 over the gate electrode 12a further improves light coupling efficiency, the AR coating being optimized for the wavelength of the incident optical radiation. Coupling efficiency may be further improved with transistor gates constructed of semitransparent electrodes such as electrodes comprised of a relatively thin layer of metal having a thickness of approximately 100 Angstroms. In accordance with an aspect of the invention the MESFETs Q1 and Q2, associated electrodes 12a, 12b, 12c and other components are formed on a common substrate 16.
The characteristics of the GaAs OPTOGLE 10 were determined with the experimental apparatus 20 schematically shown in FIG. 4. The apparatus 20 includes a pair of optical fibers 22a and 22b each of which conveys light from an associated source 24a and 24b. Sources 24a and 24b are preferably each a coherent source. An output end of each the fibers 22 is coupled to a collimating lens 26 from which the light energy is relayed to a dichroic mirror 28. Optically coupled to one side of the dichroic mirror 28 is a focusing lens 30 for focusing the outputs of the sources 24 onto respective gate electrodes of an integrated circuit device 32 containing the OPTOGLE 10. Optically coupled to the opposite side of the dichroic mirror 28 is a beamsplitter 34. An illuminator 36 for camera 40 provides illumination through a collimating lens 36. Camera 40 views the scene through a focusing lens 42. This arrangement permits the optical stimulation of the OPTOGLE 10 and the simultaneous viewing by the camera 40.
FIG. 5 illustrates the OUTPUT signal of the OPTOGLE 10. Each time division along the x-axis represents 500 picoseconds. The input pulse is the input electrical pulse applied to a laser diode source in order to generate the optical pulse that was applied to the OPTOGLE 10.
Suitable sources of radiation include mode-locked Nd:Yag lasers, Nd:YLF lasers, AlGaAs diode lasers or any source capable of generating ultrashort, fast risetime, high-peak-power optical pulses at a high repetition rate. The wavelength of the pulse is preferably within a range of wavelengths strongly absorbed by the semiconductor material For example, both GaAs and silicon strongly absorb visible and near-infrared radiation. With known types of optical pulse compression techniques using optical fibers and gratings a duration of the optical pulses can be reduced to the subpicosecond range. The GaAs MESFET-based OPTOGLE 10, although not entirely optimized for such operation, has been found to require a pulse energy of 4 pJoules. As an example, operation at 250 MHz requires an average optical power of 1 mWatt at each of the two OPTOGLE 10 receiving sites. Thus, a mode-locked laser with average output power of 1 Watt has sufficient power to simultaneously address approximately 500 of the OPTOGLE pulse converters. For example, the gate electrodes of two MESFET devices were illuminated with laser beam pulses having an approximately 30 micron spot size. The light pulses were produced by injecting a train of 250 picosecond electrical pulses into an AlGaAs diode laser having a nominal wavelength of 780 nanometers. The optical pulses were provided through fiber optics as depicted in FIG. 4.
In addition to the photo-FET implementation described in detail above the SR-F/F may be implemented in various technologies. By example, FIG. 8a shows a FET flip-flop with photodiode inputs. Preferably, the photodiodes D1 and D2 are integrated into the same substrate as the FETs Q1 and Q2 and the other components of the SR-F/F. One important advantage of this technique is the reduction of required circuit dimensions with a corresponding reduction of stray circuit reactances, both capacitive and inductive, at the photosensor leads. As a result optical input pulses are efficiently received and circuit speeds are very fast. Of course, any of the SR-F/F embodiments may be implemented with bipolar transistor technology, instead of the FET technology shown.
Also, the SR-F/F may be implemented by more general logic devices, such as the NOR gates (G1 and G2) shown in FIG. 9. This embodiment also includes integrally formed photodiodes D1 and D2 and is implemented as an integrated photosensor/logic circuit combination to achieve fast switching times.
If desired, the use of photovoltaic optical sensors such as the photodiodes D1 and D2 may be replaced, as in FIG. 8b, by integrated photoconductive sensors (S1 and S2). Such devices, such as those constructed of Group III-V, silicon and other materials exhibit very fast (picosecond) response times and are well suited for this use.
In all embodiments of the invention an important aspect is the integration of the photosensor devices with the cross-coupled switching circuitry, with no additional amplifier circuits being required or deployed, thereby significantly reducing temporal jitter in the output pulse stream.
It should be noted that for application of the OPTOGLE to a data processor that the optical pulses may be applied, as depicted in FIGS. 7a-7d, through optical fibers 50a and 50b having flat, polished ends (FIG. 7a) or integral focusing optics (FIG. 7b). In these two embodiments the fiber 50a and 50b ends are bonded or otherwise fixedly coupled to the appropriate electrode region of each of the transistors Q1 and Q2 or to the associated one of the photodiodes D1 or D2 or photoconductors S1 or S2. Either single mode or multi-mode optical fibers are suitable for this task. FIG. 7c illustrates the fibers 50a and 50b having a beveled end and coupled to a v-block. The beveled fiber ends serve as reflectors for coupling the optical inputs to, for example, the photodetectors D1 and D2. FIG. 7d illustrates an optical waveguide 54 fabricated upon the substrate 16 and having an end in optical communication with the SR-F/F for coupling optical pulses thereto. It is also within the scope of the invention to convey the optical radiation to the transistors by integrating, for example, a plurality of AlGaAs laser devices onto an integrated circuit device with the OPTOGLE 10.
OPTOGLEs may be constructed with silicon FET technology although such devices exhibit a slower response due to relatively lower carrier mobility than similar devices constructed with GaAs and/or other Group III-V materials such as InP.
By example and referring to the embodiment of FIGS. 2 and 3 with GaAs material electron mobility is approximately 8600 cm 2 /Vs and electron transit time is approximately 15 picoseconds for an electrode 12 spacing of five microns and an applied voltage of two volts. The gain is approximately 10 for laser pulses of 150 picoseconds in duration. Modulation of the gate 12a voltage during operation also results in a current amplification.
Thus, while the invention has been particularly shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that changes in form and details may be made therein without departing from the scope and spirit of the invention. | A pulse converter includes a set-reset flip/flop, or OPTOGLE 10, having a pair of cross-coupled switching devices such as transistors Q1, Q2 or logic gates G1, G2. The circuit operates by coupling pulses of optical radiation to each of the devices for causing the devices to alternately toggle between an on-state and an off-state. Optical inputting devices such as photodiodes or photoconductors, or the gates of FET transistors themselves, are integrally formed upon a common substrate with the switching devices for minimizing stray inductive and capacitive reactances to substantially eliminate temporal jitter in an electrical output signal. A pulsed laser source and a fiber optic or optical waveguide provide non-overlapping optical pulses to each of the switching devices. In accordance with one embodiment each of the switching devices is a GaAs MESFET device having a gate terminal comprised of a substantially transparent layer of electrical conductor having an interdigitated geometry and an overlying anti-reflection (AR) coating. | 7 |
FIELD OF THE INVENTION
[0001] The present invention is directed to an apparatus used in the formation of paper. More specifically the present invention is directed to an apparatus for maintaining the hydrodynamic processes involved in the formation of a fiber mat. The performance of this apparatus is not affected by the velocity of the paper machine, the basis weight of the paper sheet and or the thickness of the mat being formed.
BACKGROUND OF THE INVENTION
[0002] In general, it is well known in papermaking industry that proper drainage of liquid from the paper stock on a forming fabric is an important step to insure a quality product. This is done through the use of drainage blades or foils usually located at the wet end of the machine, e.g. a Fourdrinier paper machine. (Note the term drainage blade, as used herein, is meant to include blades or foils that cause drainage or stock activity or both.) A wide variety of different designs for these blades are available today. Typically, these blades provide for a bearing surface for the wire or forming fabric with a trailing portion for dewatering, which angles away from the wire. This creates a gap between the blade surface and the fabric which causes a vacuum between the blade and the fabric. This not only drains water out of the fabric, but also can result in pulling the fabric down. When the vacuum collapses, the fabric returns to its position which can result in a pulse across the stock, which may be desirable for stock distribution. The activity (caused by the wire deflection) and the amount of water drained from the sheet are directly related to vacuum generated by the blade, and therefore to each other. Drainage and activity by such blades can be augmented by placing the blade or blades on a vacuum chamber. The direct relationship between drainage and activity is not desirable because while activity is always desirable, too much drainage early in the sheet formation process may have adverse effects on retention of fibers and filler. Rapid drainage may also cause sheet sealing, making subsequent water removal more difficult. Existing technology forces the paper maker to compromise desired activity in order to slow early drainage.
[0003] Drainage can be accomplished by way of a liquid to liquid transfer such as that taught in U.S. Pat. No. 3,823,062 to Ward, which is incorporated herein by reference. This reference teaches the removal of liquid through sudden pressure shocks to the stock. The reference states that controlled liquid to liquid drainage of water from the suspension is less violent than conventional drainage.
[0004] A similar type of drainage is taught in U.S. Pat. No. 5,242,547 to Corbellini. This patent teaches preventing the formation of a meniscus (air/water interface) on the surface of the forming fabric opposite the sheet to be drained. This reference achieves this by flooding the vacuum box structure containing the blade(s) and adjusting the draw off of the liquid by a control mechanism. This is referred to as “Submerged Drainage.” Improved dewatering is said to occur through the use of sub-atmospheric pressure in the suction box.
[0005] In addition to drainage, blades are constructed to purposely create activity in the suspension in order to provide for desirable distribution of the flock. Such a blade is taught, for example, in U.S. Pat. No. 4,789,433 to Fuchs. This reference teaches the use of a wave shaped blade (preferably having a rough dewatering surface) to create microturbulence in the fiber suspension.
[0006] Other types of blades wish to avoid turbulence, but yet effect drainage, such as that described, for example, in U.S. Pat. No. 4,687,549 to Kallmes. This reference teaches filling the gap between the blade and the web and states that the absence of air prevents expansion and cavitation of the water in the gap and substantially eliminates any pressure pulses. A number of such blades and other arrangements can be found in the following prior art: U.S. Pat. Nos. 5,951,823; 5,393,382; 5,089,090; 4,838,996; 5,011,577; 4,123,322; 3,874,998; 4,909,906; 3,598,694; 4,459,176; 4,544,449; 4,425,189; 5,437,769; 3,922,190; 5,389,207; 3,870,597; 5,387,320; 3,738,911; 5,169,500 and 5,830,322, which are incorporated herein by reference.
[0007] Traditionally, high and low speed paper machines produce different grades of paper with a wide range of basis weights. Sheet forming is a hydromechanical process and the motion of the fibers follow the motion of the fluid because the inertial force of an individual fiber is small compared to the viscous drag in the liquid. Formation and drainage elements affect three principle hydrodynamic processes, which are drainage, stock activity and oriented shear. Liquid is a substance that responds according to shear forces acting in or on it. Drainage is the flow through the wire or fabric, and it is characterized by a flow velocity that is usually time dependant.
[0008] Stock activity, in an idealized sense, is the random fluctuation in flow velocity in the undrained fiber suspension, and generally appears due to a change in momentum in the flow due to deflection of the forming fabric in response to drainage forces or as being caused by blade configuration. The predominant effect of stock activity is to break down networks and to mobilize fibers in suspension. Oriented shear and stock activity are both shear-producing processes that differ only in their degree of orientation on a fairly large scale, i.e. a scale that is large compared to the size of individual fibers.
[0009] Oriented shear is shear flow having a distinct and recognizable pattern in the undrained fiber suspension. Cross Direction (“CD”) oriented shear improves both sheet formation and test. The primary mechanism for CD shear (on paper machines that do not shake) is the creation, collapse and subsequent recreation of well defined Machine Direction (“MD”) ridges in the stock of the fabric. The source of these ridges may be the headbox rectifier roll, the head box slice lip (see e.g., International Application PCT WO95/30048 published Nov. 9, 1995) or a formation shower. The ridges collapse and reform at constant intervals, depending upon machine speed and the mass above the forming fabric. This is referred to as CD shear inversion. The number of inversions and therefore the effect of CD shear is maximized if the fiber/water slurry maintains the maximum of its original kinetic energy and is subjected to drainage pulses located (in the MD) directly below the natural inversion points.
[0010] In any forming system, all these hydrodynamic processes may occur simultaneously. They are generally not uniformly distributed in either time or space, and they are not wholly independent of one another, they interact. In fact, each of these processes contributes in more than one way to the overall system. Thus, while the above-mentioned prior art may contribute to some aspect of the hydrodynamic processes aforesaid, they do not coordinate all processes in a relatively simple and effective way.
[0011] Stock activity in the early part of a Fourdrinier table is critical to the production of a good sheet of paper. Generally, stock activity can be defined as turbulence in the fiber-water slurry on the forming fabric. This turbulence takes place in all three dimensions. Stock activity plays a major part in developing good formation by impeding stratification of the sheet as it is formed, by breaking up fiber flocks, and by causing fiber orientation to be random.
[0012] Typically, stock activity quality is inversely proportional to water removal from the sheet; that is, activity is typically enhanced if the rate of dewatering is retarded or controlled. As water is removed, activity becomes more difficult because the sheet becomes set, the lack of water, which is the primary media in which the activity takes place, becomes scarcer. Good paper machine operation is thus a balance between activity, drainage and shear effect.
[0013] The capacity of each forming machine is determined by the forming elements that compose the table. After a forming board, the elements which follow have to drain the remaining water without destroying the mat already formed. The purpose of these elements is to enhance the work done by the previous forming elements.
[0014] As the basis weight is increased the thickness of the mat is increased. With the actual forming/drainage elements it is not possible to maintain a controlled hydraulic pulse strong enough to produce the hydrodynamic processes necessary to make a well-formed sheet of paper.
[0015] An example of conventional means for reintroducing drainage water into the fiber stock in order to promote activity and drainage can be seen in FIGS. 1-7 .
[0016] A table roll 100 in FIG. 1 causes a large positive pressure pulse to be applied to the sheet 96 , which results from water 94 under the forming fabric 98 being forced into the incoming nip formed by the lead in roll 92 and forming fabric 98 . The amount of water reintroduced is limited to the water adhered to the surface of the roll 92 . The positive pulse has a good effect on stock activity; it causes flow perpendicular to the sheet surface. Likewise, on the exiting side of the roll 90 , large negative pressures are generated, which greatly motivate drainage and the removal of fines. But reduction of consistency in the mat is not noticeable, so there is little improvement through increase in activity. Table rolls are generally limited to relatively slower machines because the desirable positive pulse transmitted to the heavy basis weight sheets at specific speeds becomes an undesirable positive pulse that disrupts the lighter basis weight sheets at faster speeds.
[0017] A gravity foil 88 is shown in FIG. 2 . The vacuum generated by a foil blade 86 increases with an increase in the foil angle and or the blade length. The vacuum, in this case, increases in direct proportion to the square of the machine speed. The vacuum forces generated by a foil blade increase as fiber mat 96 drainage resistance increases. Low foil blade angles, often in the range of about 0.5 to 1 degree, are used in the early part of the forming table. The angle is increased to the dry end of the table up by 3 to 4 degrees. As less water is available in machine direction, the angle selected should allow the ability of the diverging gap to be filled with water.
[0018] FIGS. 3 to 7 show low vacuum boxes 84 with different blade arrangements. A gravity foil is also used in low vacuum boxes. These low vacuum augmented units 84 provide the papermaker a tool that significantly affects the process by controlling the applied vacuum and the pulse characteristics. Examples of blade box configurations include:
[0019] Gravity foil or foil blade box 88 as shown in FIG. 2 ;
[0020] Flat blades or wet box (not shown);
[0021] Step blades 82 as show in FIGS. 3-5 , and 7 ;
[0022] Offset plane blade 80 as shown in FIG. 6 ; and
[0023] Positive pulse step blade 78 as shown in FIG. 7 .
[0000] Traditionally, the foil blade box, the offset plane blade box and the step blade box are mostly used in the forming process.
[0024] In use, a vacuum augmented foil blade box will generate vacuum as the gravity foil does, the water is removed continuously without control, and the predominant drainage process is filtration. Typically, there is no refluidization of the mat that is already formed.
[0025] In a vacuum augmented flat blade box, a slight positive pulse is generated over the blade/wire contact surface and the pressure exerted on the fiber mat is due only to the vacuum level maintained in the box.
[0026] In a vacuum augmented step blade box, as shown in FIG. 3 , a variety of pressure profiles are generated depending upon factors such as, step length, span between blades, machine speed, step depth, and vacuum applied. The step blade generates a peak vacuum relative to the square of the machine speed in the early part of the blade, this peak negative pressure causes the water to drain and at the same time the wire is deflected toward the step direction, part of the already drained water is forced to move back into the mat refluidizing the fibers and breaking up the flocks due to the resulting shear forces. If the applied vacuum is higher than necessary, the wire is forced to contact the step of the blade, as shown in FIG. 4 . After some time of operation in such a condition, the foil accumulates dirt 76 in the step, losing the hydraulic pulse which is reduced to the minimum, as shown in FIG. 5 , and prevents the reintroduction of water into the mat.
[0027] The vacuum augmented offset plane blade box, as shown in FIG. 6 has leading/trailing and intermediate flat blades 80 at two different elevations below the wire line. The intermediate blade 80 is set below the wire line to limit the deflection of the wire under vacuum and creates a hydrodynamic nip with the water under the forming wire.
[0028] The vacuum augmented positive pulse step blade low vacuum box, as shown in FIG. 7 , fluidizes the sheet by having each blade reintroduce part of the water removed by the preceding blade back into the mat. There is, however, no control on the amount of water reintroduced into the sheet.
[0029] While some of the foregoing references have certain attendant advantages, further improvements and/or alternative forms, are always desirable.
SUMMARY OF THE INVENTION
[0030] It is an object of the present invention to provide a machine for maintaining the hydrodynamic processes of a paper sheet formed thereon.
[0031] It is a further object of the present invention to provide a machine usable with a forming board and or a velocity induce drainage machine.
[0032] It is a further object of the present invention that the efficiency of the machine not be affected by the velocity of the machine, the basis weight of the paper sheet and or the thickness of the mat.
[0033] The various features of novelty which characterize the invention are pointed out in 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 mater in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The following detailed description, given by way of example and not intended to limit the present invention solely thereto, will best be appreciated in conjunction with the accompanying drawings, wherein like reference numerals denote like elements and parts, in which:
[0035] FIG. 1 Depicts a known table roll;
[0036] FIG. 2 Depicts a known gravity foil blade;
[0037] FIG. 3 Depicts a known low-vacuum box with step blade;
[0038] FIG. 4 Depicts a known low-vacuum box with step blade, wire touching the step;
[0039] FIG. 5 Depicts a known low-vacuum box, step blade with dirt accumulation;
[0040] FIG. 6 Depicts a known offset-plane blade low-vacuum box;
[0041] FIG. 7 Depicts a known positive pulse blade low vacuum box;
[0042] FIG. 8 Depicts a blade according to one aspect of the instant invention;
[0043] FIG. 9 Depicts a blade according to FIG. 8 with the support for blade 4 removed for clarity;
[0044] FIG. 9 a Depicts a blade according to FIG. 9 with an offset section for control of drainage according to another aspect of the invention;
[0045] FIG. 10 Depicts a blade according to another aspect of the instant invention;
[0046] FIG. 10 a Depicts a blade according to FIG. 10 with a multi-angled microactivity zone;
[0047] FIG. 10 b Depicts a blade according to FIG. 10 with pivot point;
[0048] FIG. 10 c Depicts a profile view of a blade and support as shown in FIG. 10 ;
[0049] FIG. 10 d Depicts a profile view of a blade as shown in FIG. 10 with an alternative support;
[0050] FIG. 10 e Depicts a top view of a support blade usable with the blade shown in FIG. 10 ;
[0051] FIG. 10 f Depicts a cross-sectional view of the support blade of FIG. 10 e at a point where the support is open to allow flow of water through the support;
[0052] FIG. 10 g Depicts a cross-sectional view of the support blade of FIG. 10 e at a point where the support blade is closed by the support 4 d;
[0053] FIG. 10 h Depicts a side view of the support blade of FIG. 10 e;
[0054] FIG. 11 Depicts a blade, according to another aspect of the instant invention;
[0055] FIG. 12 Depicts a blade, according to another aspect of the instant invention;
[0056] FIG. 13 Depicts a blade, according to another aspect of the instant invention;
[0057] FIG. 14 Depicts a blade, according to another aspect of the instant invention;
[0058] FIG. 15 Depicts a blade, according to another aspect of the instant invention;
[0059] FIG. 15 a Depicts a blade as shown in FIG. 14 having multiple main body portions between foils;
[0060] FIG. 15 b Depicts a blade as shown in FIG. 15 a having pivot points on the main bodies;
[0061] FIG. 15 c Depicts a blade as shown in FIG. 14 , having elongated and multiple activity zones;
[0062] FIG. 15 d Depicts a blade as shown in FIG. 15 c having pivot points;
[0063] FIG. 16 Depicts the hydraulic performance of a blade, according to one aspect of the present invention;
[0064] FIG. 17 Depicts the hydraulic performance of a blade, according to one aspect of the present invention;
[0065] FIG. 18 Depicts the hydraulic performance of a blade, according to one aspect of the present invention;
[0066] FIG. 19 Depicts the hydraulic performance of a blade, according to one aspect of the present invention;
[0067] FIG. 20 Depicts the hydraulic performance of a blade, according to one aspect of the present invention;
[0068] FIG. 20 a Depicts the hydraulic performance of a blade, according to another aspect of the present invention;
[0069] FIG. 21 Depicts water flow in a blade, according to one aspect of the present invention;
[0070] FIG. 22 Depicts water flow in a blade, according to one aspect of the present invention;
[0071] FIG. 23 Depicts water flow in a blade, according to one aspect of the present invention;
[0072] FIG. 24 Depicts water flow in a blade, according to one aspect of the present invention;
[0073] FIG. 25 Depicts a detailed view of blade geometry, according to at least one aspect of the present invention;
[0074] FIG. 26 Depicts the blade geometry bases for calculating pressure, according to one aspect of the present invention;
[0075] FIG. 27 Depicts the blade geometry bases for calculating pressure, according to another aspect of the present invention; and
[0076] FIG. 28 Depicts water flow in a blade, according to one aspect of the present invention.
DETAILED DESCRIPTION
[0077] One aspect of the instant invention can be seen with reference to FIGS. 8 , 9 , 9 a , 10 , 10 a and 10 b . In FIG. 8 , the body 3 includes a leading edge 3 a which contacts the forming fabric 2 . As shown in FIG. 8 the leading edge 3 a in contact with the forming fabric is flat and parallel to the forming fabric 2 . In this example, it is desirable that the leading edge 3 a have full contact with the forming fabric. Following the leading edge 3 a is a diverging surface 3 b , which slopes away from the leading edge 3 a . The angle of the diverging surface with respect to the leading edge is preferably within the range of about 0.1 to 10 degrees. However, it is preferred that the angle be less than 10 degrees.
[0078] Next, there is a channel 5 which leads to a controlled turbulence zone 8 and then to a micro-activity zone 12 . The micro-activity zone 12 may be flat as is shown in FIGS. 8 and 9 , or may include a step 15 as shown in FIG. 10 to create controlled turbulence. Alternatively, the micro-activity zone 12 may have a divergent section 12 c and a convergent section 12 d , as shown in FIGS. 10 a and 10 b . The divergent section 12 c has an angle α to horizontal and the convergent section 12 d has an angle β to the horizontal. The angles α and β may be the same or preferably different to optimize the activity in the micro-activity zone. The micro-activity zone 12 may also include an offset plane 12 a in order to retain water for activity improvement and control as show in FIG. 9 a . In practice, the use of a flat, angled, or stepped micro-activity zone will depend on the machine speed, consistency of the mat and its basis weight.
[0079] Between the channel 5 and the micro-activity zone 12 , there is a support blade 4 . The support blade 4 helps to maintain the forming fabric 2 separated from the body 3 (or 3 and 16 as shown in FIG. 15 , which will be described below). The support blade 4 also forms channel 5 . The channel 5 allows water 7 to drain from the fiber slurry 1 , through the fabric 2 and move towards the controlled turbulence zone 8 followed by the micro-activity zone 12 . The support blade 4 is set in place by the spacers 14 and fixed by the bolts 6 and spacers 14 . Bolts 6 are evenly distributed across the machine width in such a fashion that the support blade is not deflected and no disturbing streams are created. Following the micro-activity zone 12 , where the forming fabric 2 comes closest to contacting the blade, water is drained into drain 10 .
[0080] Another aspect of the present invention is shown in FIGS. 10 c and 10 d , where a support blade 4 a is shown in greater detail. FIGS. 10 c and 10 d are cross sectional view of a blade taken at different locations across the cross-machine direction of the blade. In FIG. 10 c , the cross-section is taken along a portion of the support blade 4 a where the spacer 4 b is located. This in cross-section FIG. 10 c shows a substantially solid support blade 4 a . In contrast, FIG. 10 d shows a cross-section taken along a different portion of the support blade 4 a at a location where there is no spacer 4 b , but rather a channel 5 through the support blade 4 a for allowing the flow of water under the support blade 4 a . Further details of this aspect of the invention can be seen with reference to FIGS. 10 e - h , where top, cross-sectional and front views are shown, respectively. The spacers 4 b preferably have a substantially rounded shape, as shown in FIG. 10 e , to promote stable flow of water through the channel 5 . The supports 4 b are preferably evenly distributed across the entire width 4 e . Such a configuration will ease in the installation or replacement of the support blade 4 a , which is preferably made in one piece as shown in FIGS. 10 a - h.
[0081] In practice another blade 11 may be installed immediately following the drain 10 . A leading edge of the second blade 11 can be seen in FIG. 8 . The number of blades necessary on the forming table is dependant on the thickness T of the fiber slurry 1 , consistency of the stock, basis weight, retention and the machine speed.
[0082] A variety of configurations are possible using different aspects of the present invention including:
1. Blades with a flat surface 12 , as shown in FIG. 11 ; 2. Blades with a step 15 , as show in FIG. 12 ; 3. Alternating blades with a step 15 and a flat surface 12 , as show in FIG. 13 ; 4. Blades with the lead in edge 16 that is actually removed from the rest of the blade and has a leading edge that angles away from the forming fabric in combination with a flat surface 12 , as show in FIG. 14 ; 5. Blades with the lead in edge 16 that is actually removed from the rest of the blade and has a leading edge that angles away from the forming fabric in combination with a step 15 , as shown in FIG. 15 ; 6. Blades with the lead in edge 16 removed from the rest of the blade and having a leading edge that angles away from the forming fabric with the activity zone formed of a converging and diverging sections 12 d , 12 c either with or without a pivot point 22 as shown in FIGS. 15 a and 15 b ; or 7. A blade 24 , 25 with an elongated micro-activity zone having multiple diverging and converging sections 12 c , 12 d either with or without a pivot point 22 as shown in FIGS. 15 c and 15 d.
[0090] Other arrangements of the blades according to certain aspects of the instant invention are also possible within the scope of the instant invention.
[0091] The blade as shown in FIGS. 8 , 9 , 9 a , 10 , 10 a and 10 b , performs one forming cycle where the necessary hydrodynamic processes to form the sheet of paper take place. At the leading edge 3 a , a positive pulse P 1 is created that produces shear effect. At the diverging surface 3 b , the water 7 drains from the sheet or fiber slurry 1 due to increase in kinetic energy and reduction of potential energy. This is the second hydrodynamic process on the blade. Next, support blade 4 creates a second positive pulse P 2 which is similar to P 1 . The drained water 7 follows in continuation through channel 5 . Part of the drained water is then reintroduced to the sheet 2 in the micro activity zone 12 and the controlled turbulence zone 8 . Draining continues with water exiting the blade through drain 10 . Therefore, three hydrodynamic processes take place within one forming cycle in these sections of the blade.
[0092] FIG. 10 b shows a pivot point 22 which allows the trailing portion of a blade 23 to be adjusted as necessary, according to the operating parameters of the device. FIG. 15 c depicts a further aspect of the invention having multiple cycles of diverging and converging angled sections on a single long blade 25 . These multiple cycles help preserve activity in the early part of the forming table. FIG. 15 d depicts the same multi-cycle blade 24 formed with a pivot point 22 .
[0093] The thickness T of the slurry 1 does not affect the performance of the support blade 4 or the velocity of the machine. In practice, the dimensions of the steps A and B of the first stage, shown in FIG. 25 , are sized according to the thickness of the slurry and the velocity of the machine. As such, because step A can be adjusted by adjusting support blade 4 , the properties of the device can be optimized for a particular stock thickness and machine speed.
[0094] As a result of the hydrodynamic process performed by the blade, and the reintroduction of water in the early part of the blade, the following improvements may be obtained by the present invention:
I. There is no filtration process in the early part of the blade; II. The power necessary to drive the wire is reduced because there is no drag created by the wire acting on the blade, as the blade is supported by the water along its length; III There is no dirt accumulation on the blade because there is continuous flow of water; IV. The fibers on the wire are redistributed and activated with the same water; V. Fines retention is increased and evenly distributed across the thickness of the sheet; VI. Formation is improved; VII. Squareness of the sheet is controlled as is necessary; VIII. Drainage is controlled, and the filtration process may be eliminated; and IX. Physical properties of the paper are improved or controlled as are necessary.
[0104] FIGS. 14 and 15 show a further aspect of the present invention, where the leading edge 3 is separated from the main body 16 of the blade. This configuration is useful in machines when either drainage has been done in previous elements without water removal, or there is limited space on the forming table, allowing greater, yet controlled amounts of water to be removed from the fibrous slurry 1 .
[0105] FIGS. 16 , 17 , 18 , 19 , 20 , and 20 a show the hydraulic performance of blades according to certain aspects of the instant invention. In FIG. 16 , in section 3 a a positive pulse P 1 is created that produces shear effect. The diverging section 3 b drains water 7 due to increase in kinetic energy and reduction of potential energy. This is the second hydrodynamic process on the blade. The support blade 4 creates a second positive pulse P 2 which is similar to P 1 . The drained water 7 follows continuously through channel 5 .
[0106] In FIG. 17 , the water 7 is drained by a foil 17 which has the leading edge 3 a and the diverging section 3 b , located on a separate portion of the blade. Again, the leading edge 3 a of the foil 17 creates a positive pulse P 1 and produces a shear effect. The diverging section 3 b drains water 7 from the fibrous slurry to promote activity, which flows continuously through channel 5 . Again the support blade 4 creates a pulse P 2 (Alternating positive pulses that creates shear effect on cross machine direction) that is similar to P 1 .
[0107] FIGS. 18 , 19 20 , and 20 a , show the hydrodynamic effects of: a flat micro-activity zone in FIG. 18 ; a micro-activity zone with an offset plane in FIG. 19 ; and a stepped micro-activity zone in FIG. 20 . In each of these figures, part of the drained water 7 is reintroduced to the sheet 1 in the micro activity zone 12 and/or in the controlled turbulence zone 8 . Continuation drainage also takes place. As discussed above, shear is created at the leading edge 3 a and the support blade 4 produces pulses P 1 and P 2 . When water 7 is reintroduced in section 8 , the fibers are redistributed, thereby creating activity in section 8 . Where necessary, fine shear may be created with the use of a step 15 , as shown in FIG. 20 . To increase the micro-activity in the micro-activity zone 12 , an offset plane 12 a may be employed to retain additional water as necessary. The micro-activity zone 12 is comprised of offset sections 12 a and 12 b . These offset sections may be flat or angled. The final design of the offset sections 12 a and 12 b depends on the thickness of the slurry and the machine speed. Typically, drainage is controlled in late part of sections 12 , 12 a and 12 b.
[0108] FIG. 20 a shows an arrangement capable of operation without additional vacuum. This is possible by use of the diverging section 12 c and the converging section 12 d , discussed above. In use, the diverging section 12 d creates a vacuum by the angle of the divergence causing a loss in potential energy. This created vacuum then draws water from the stock. A portion of the water is then reintroduced by the converging section 12 d and creates activity in the stock. However, a larger portion of the water is drained by drain 10 .
[0109] In FIG. 21 a further aspect of the instant invention is depicted. The water 7 that flows through channel 5 forms stream lines 19 in section 21 . As long as the hydraulic cross section of the flow path of the water 7 is being continuously reduced, the water 7 is forced into and is reintroduced through the forming wire 13 and into the fiber slurry 1 . The force of the reintroduced water 7 may deflect the forming fabric 13 . However, this is countered, at least to some degree, by the vacuum generated by the increase in the kinetic energy. In section 18 , fiber activity and shear effect are generated and as a consequence, the fiber mat formation is improved. Unlike some of the known methods of sheet production described above, the forming fabric 12 does not contact the surface of the micro-activity zone 12 because of continuous water flow through channel 5 . As a result, the sheer and fiber activity in the sheet 1 are not interrupted.
[0110] In FIG. 22 , in an attempt to retain a certain portion of the water 7 for the micro-activity zone 12 , there is an offset plane that includes portions 12 a and 12 b . Portion 12 b may be designed at an angle that may be between 0.1 to 10 degree in order to control drainage. The preferred range for the angle of portion 12 b is between 1 and 3 degrees.
[0111] FIG. 23 depicts a blade that uses a step 15 to produce high levels of turbulence. The actual dimensions of the step 15 are dependant on the thickness of the slurry, consistency of the slurry and the machine speed.
[0112] FIG. 24 depicts the stream lines 19 of water flow that occur as the forming fabric passes over the step 15 . As can be seen, eddy currents are formed in the machine direction and are created along the entire machine width. The eddy currents will generally be in a clockwise rotation, when observing a device having a machine direction as shown in FIG. 24 . The flow of water 7 becomes stable at the reconnection point. The dimension of the counter flows zone will depend on the machine speed, step size and the amount of water on the step. The eddy currents create high levels of turbulence and differential velocities between the fiber slurry and the eddy currents. This action breaks the flocks of fibers, thereby redistributing the fibers and improving paper formation.
[0113] Another aspect of the instant invention is directed to blade geometry. In FIG. 25 , the area between the exit side of support blade 4 and the lead in edge of the following blade 11 is where the shear, activity and drainage occur (the three hydrodynamic processes needed to form the paper sheet). Side A of the blade is where hydrodynamic shear and activity are developed, and drainage occurs at side B of the blade. The first stage is from the exit side of support blade 4 to the edge of the step 15 . Step A is sized according to the amount of water coming from previous elements and the water drained at this stage. In the first stage, water is reintroduce to the fiber slurry 1 and high shear effect is developed. From the beginning of the second stage up to the maximum point of wire deflection, high activity is developed due to the eddy currents at the step and the instantaneous differential velocities between the water 7 and the forming fabric 13 . Side A is the higher pressure side of the blade and thus water will always flow in direction towards side B of the blade, ultimately resulting in drainage.
[0114] FIG. 26 provides a model for determining the dynamic pressure developed on the forming fabric, which can be calculated by the following equation:
[0000]
K
4.
·
m
2
+
c
2
·
m
·
Vm
2
[0115] where ‘m’ is deflection of the wire in inches, ‘c’ is the span of the wire in inches, ‘Vm’ is the machine speed in feet per minute, and ‘K’ is a constant, of value 0.82864451984491991898e-3.
[0116] The dynamic pressure developed on the forming fabric is proportional to the gravitational or centrifugal force experienced by the forming fabric, which is commonly referred to as the ‘g-force’, and usually lies in the range of 1 to 10, however, values between 3 and 5 are preferable.
[0117] Those of skill in the art will recognize that other values for ‘K’ can be used to undertake this calculation without departing from the scope of the present invention, however, the value provided above has been determined to be preferable.
[0118] FIG. 27 shows a close-up view of a blade having converging and diverging sections 12 c and 12 d , respectively. Though shown herein as having the same length C 1 and C 2 , these lengths may be optimized as necessary for the production process. Further, the angles, a and B, can be optimized for creation of vacuum and reintroduction of water into the stock respectively.
[0119] Finally, FIG. 28 generally shows the flow pattern of water entrained in the stock as the wire passes 2 over the support blade 4 and through the diverging and converging sections 12 c and 12 d . As can be seen, water is removed and reintroduced into the stock at several locations along the blade.
[0120] While the invention has been described in connection with what is considered to be the most practical and preferred embodiment, it should be understood that this invention is not limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | The invention relates to an apparatus used in the formation of paper. More specifically the present invention is directed to an apparatus for maintaining the hydrodynamic processes involved in the formation of a fiber mat or paper sheet. The performance of this apparatus is not affected by the velocity of the paper machine, the basis weight of the paper sheet and or the thickness of the mat being formed. | 3 |
FIELD OF THE INVENTION
The present invention relates to fluorescent lamps; and more particularly, it relates to a portable fluorescent lamp for use in special applications. As used herein, "special applications" is intended as a broad term which refers to use environments other than the normal domestic, commercial or industrial use.
BACKGROUND OF THE INVENTION
Special applications include use in damp, or even wet applications, as are found in food plants, for example, where a salt spray might be used and produce a constant mist, or in chemical plants, or in manufacturing environments where volatile or inflammable solvents are used in the manufacturing process. In the damp or wet environments, the problem of corrosion exists with attendant reduction in the life of the fixture. In hazardous environments, safety requirements dictate that the possibility of an electrical discharge or spark be accounted for and either eliminated or encapsulated so that it is isolated from the environment in which the fixture is used. Alternatively, operating circuits may be designed to operate at inherently safe power levels, as discussed further below.
For brevity, reference will be made more frequently herein to hazardous environment application than wet, damp or other special applications. Persons skilled in the art will readily appreciate the facility with which the present invention is accommodated to many-different applications. One application where the present invention might have particular utility, as an example, might be a manufacturing plant for aircraft or a petroleum refinery where the use of volatile solvents and other flammable liquids or fumes are present. In most of these applications, it is desirable that the lighting be portable. From the user's standpoint, it is also desirable that the fixture be capable of being re-lamped without the use of special tools or devices because unless substitute lighting is available, when a lamp burns out, production may have to be curtailed or shut down, and safety may be compromised if supplemental light is not available.
Lighting has been designed for hazardous duty applications using incandescent lamps. However, incandescent lamps, particularly those capable of generating larger outputs of light, operate at fairly high temperatures, and therefore may create another potential hazard, particularly in an environment of volatile materials. Fluorescent lamps have also been incorporated in lighting for hazardous applications. However, fluorescent lamps typically require one hundred volts or more to initiate discharge, as well as for continual operation. Thus, precautions have to be made to reduce the possibility of arcing.
Conventional fluorescent lamps have electrodes passing through the glass envelope for connecting to the power source. In order to be able to replace the lamp, the electrodes are mounted in sockets in such a manner that they normally are exposed to the environment, again, unless special precautions are taken.
In some designs employing conventional fluorescent lamps, where leads, terminals, circuit elements or electrodes are exposed to the environment, designers have designed circuitry to operate at "intrinsically safe" power levels. This term is known in the art and refers to predetermined operating levels of voltage and current for switching circuits to insure that arcing will not occur. Although circuit designs can incorporate requirements for inherently safe circuit operation, that is not the case for fluorescent lamps and it becomes next to impossible to achieve an inherently safe control or ballast circuit for a conventional fluorescent lamp wherein the entire control and power system operates at inherently safe levels and still permit the fixture to be conveniently re-lamped. Thus, whereas operating or control circuits may operated at inherently safe levels, the power portions of circuitry for conventional fluorescent lighting cannot, and some other provisions (such as air purging) must be made for operation of conventional fluorescent lamps in hazardous environments.
One attempt to overcome the problems associated with operating conventional fluorescent lamps in a hazardous environment is described in the co-pending application of Baggio and Granat entitled AIR PURGED PORTABLE ELECTRIC LAMP, Ser. No. 431,308, filed Apr. 28, 1995. In that application, the fluorescent lamps and the power source are housed in an enclosure which is purged with breathable air before power is applied to the fluorescent lamp. Although these devices have been useful and represent an advance in the art, they require a separate source of breathable air, conduit or tubing routing the air from the source to the location of use, and circuitry for controlling the purging cycle and sensing when the breathable air is not flowing through the enclosure to purge the interior of the enclosure. Moreover, because the lamps are housed in a sealed environment except for the entrance and discharge of the breathable air, it normally requires that the fixtures be taken out of use and lamps replaced at a remote location where tools and the like are required.
Electrodeless lamp technology has been developed in which electrodes do not pass through the glass envelope of a fluorescent lamp. However, electrodeless lamp technology to date has been directed primarily to domestic or commercial applications in which the RF source, coupling mechanism and lamp are all integrated into a screw-type base so that it might replace the conventional incandescent lamp, such as is shown, for example, in U.S. Pat. Nos. 4,171,378 and 5,220,236. Other examples of the application of electrodeless lamp technology have characteristics similar to these two applications which prevent their use in hazardous or wet locations, for example, because the attempt has been to integrate the power source integrally with the lamp, leaving some portion of the input power supply lines, power supply or coupler in contact with, or not sealed from the environment in which the fixture is intended to operate.
SUMMARY OF THE INVENTION
The present invention is directed to a modification of the electrodeless lamp technology which enables it to be useful in special applications such as the ones mentioned above. According to the present invention, a fluorescent lamp includes an electrodeless envelope of glass or other light-transmissive material carrying fluorescent material within the envelope. An RF energy source and coupler are embedded in epoxy as an integral power unit, isolated from the environment. The power supply line coupling a conventional energy source to the RF energy source has the connection to the RF energy source also embedded in epoxy.
The power unit and the envelope are shaped in complementary form such that the coupler and envelope are in energy-transfer relation to excite the lamp during use, but they are separated by the sealant. Thus, the envelope, though it may be mechanically mounted to the epoxy-covered power unit, may also be removed from the power unit to re-lamp the fixture.
One advantage of the present invention, then, is that all of the fixture which has any electrical voltage or current is completely embedded in epoxy. Epoxy is recognized as a substance which creates a seal or encapsulation which permits electrical circuitry to operate safely (i.e. without fear of spark) even in hazardous environments. Not only is the possibility of a spark eliminated, but corrosion normally associated with salt environments and other environments having corrosive chemicals or volatile materials, is eliminated.
Another advantage of the present invention is that re-lamping can be made simple and direct without the use of special locations, and the fixture can be re-lamped right in the hazardous environment so that any interruption in the manufacturing process is kept to a minimum.
Another advantage of the present invention is that it is much more flexible and adaptable to different use applications since it does not have the bulk of conventional fluorescent tubes with their awkward length.
Other features and advantages of the present invention will be apparent to persons skilled in the art from the following detailed description of a preferred embodiment accompanied by the attached drawing wherein identical reference numerals will refer to like parts in the various views.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a diagrammatic view of a first electrodeless lamp including a electromagnetic coupler according to the present invention;
FIG. 2 is a diagrammatic view of a second embodiment of an electrodeless lamp incorporating a magnetic coupler constructed according to the present invention;
FIG. 3 is a diagrammatic view of a third embodiment of an electrodeless lamp incorporating a capacitive coupler constructed according to the present invention;
FIG. 4 is a cross section taken through the sight line B--B of FIG. 3; and
FIG. 5 is a side view of a portable hand lamp constructed according to the present invention and incorporating an electromagnetic radiation shield.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, reference numeral 10 generally designates a diagrammatic outline of a light-transmissive envelope of a globular fluorescent lamp of the type commonly referred to as electrodeless. The envelope 10, which preferably may be of glass or other light-transmissive material, is filled with an ionizable gas (for example, a mixture of a rare gas such as krypton and/or argon and mercury vapor and/or cadmium vapor). The interior surface of the envelope 10 are coated in a well-known fashion with a suitable phosphor which, when stimulated or excited by an electromagnetic field, emits visible radiation upon absorption of ultraviolet radiation, in a manner similar to that in which conventional fluorescent lamps operate.
In the illustrated embodiment, the envelope 10 has a portion formed into a cavity 12 for receiving a portion of an RF power unit generally designated 11. Power unit 11 includes an RF power source and a coupler. In the embodiment of FIG. 1, an electromagnetic coupling element is generally designated 13. The electromagnetic coupler 13 includes a core 14 in the form of a ring, and which may be formed in a toroidal shape having a generally round and uniform cross section. A winding 15 is wound around the core 14 and energized by a conventional source of RF current generally designated 17. The structure thus far described is disclosed in U.S. Pat. No. 4,117,378, which disclosure is incorporated herein by reference. In that patent, however, the glass envelope and RF power source are integrally mounted into a base which is provided with a conventional screw-type mounting for conventional sockets.
In the illustrated embodiment, on the other hand, a flexible power cord 20, which may be coupled to a conventional plug adapted to be received in a wall socket, for example (not shown for brevity) couples power to the RF source 17. The RF source and terminal end of the power cord 20 (i.e., the entire power unit), as well as the leads from the RF power source 17 to the winding 15 and the electromagnetic coupler itself, are all encased in epoxy. The envelope of the epoxy covering is diagrammatically illustrated by the solid line 22; and it encompasses, covers and seals all of the elements carrying an electrical voltage or circuit which could in any way be directly exposed to the environment in which the fixture shown in FIG. 1 may be used. Moreover, that portion of the epoxy covering 22 which covers the coupler 13 is molded to be received in and engage the surface of the cavity 12 of the envelope 10 so that the electromagnetic coupler 13 is properly positioned inside the lamp envelope 10 for use in accordance with the teachings of the prior art. That is, the coupler 13 generates a radio frequency magnetic field within the core 14 when excited by the RF power source 17. The resulting magnetic field induces a solenoidal electric field in the ionizable gas contained within the envelope 10. The RF magnetic field ionizes the gas within the envelope and stimulates the emission of ultraviolet radiation from the gas, and the ultraviolet radiation impinges on the phosphor deposited within the lamp 10 for generating visible light.
In the embodiment illustrated in FIG. 1, the envelope 10 seats firmly and snugly on the portion of the power unit 11 which encompasses the magnetic coupler, so that if the lamp 10 becomes non-functional, it may be replaced. However, additional structure can be provided so that the envelope 10 and the coupler 13 may be more securely, but removably coupled together. The provision of the epoxy covering 22 and the flexible power cord 20 to the RF power source 17 permit the fixture shown in FIG. 1 to be portable, and yet to be adaptable for either a hazardous location, a damp location, or even a wet location. In fact, it may be submersed in water without deleterious effect on the RF power source or the magnetic coupler 13, though the unit shown is not intended for continuous underwater use.
Turning now to the embodiment of FIG. 2, the glass envelope is again designated by reference numeral 10 and the power unit 11. The envelope is provided with a cavity 12A for receiving electromagnetic coupler 13A comprising coil formed from a winding 15A which surrounds a torroid (not shown) and excited by an RF power source 17a.
In the embodiment of FIG. 2, the winding 15A forms a coil 25 having spiral turns and defines a generally vertical axis parallel to the axis of the elongated socket 12a. Again, RF current flows through the winding 15A and establishes a radio frequency magnetic field about the coil 25 (in the form of a toroid having a mid-plane lying horizontally and perpendicular to the plane of the page of FIG. 2). The RF electromagnetic field induces an electric field within the envelope 10. The field ionizes and excites the gas within the envelope resulting in a discharge which generates ultraviolet radiation which is absorbed by and excites the phosphor coating on the interior surface of the envelope, thereby stimulating the emission of a visible radiation by the lamp envelope.
As in the embodiment of FIG. 1, the flexible power cord 20 coupling conventional alternating voltage to the RF power source 17A, the RF power source 17A itself, the lead 15A and the winding 25 are all encapsulated by and embedded within epoxy material 22A.
Turning now to the embodiment of FIG. 3, a fluorescent lamp is generally designated 28, and it is in the form of a cylindrical tube which is bent at its mid-section to form an inverted U. This configuration is conventional and is sometimes referred to as a "twin tube" or a biaxial lamp. The inclusion of phosphors deposited on the interior of the glass envelope and the ionizable gases is the same as other fluorescent lamps. However, there is no starter or filament. Rather, the coupler in this case, which is generally designated as numeral 30 is a capacitive coupler.
The capacitive coupler 30 includes an RF power source 31, and first and second ring electrodes 32, 33 which surround respectively the adjacent free ends 28A, 28B of the biaxial tube 28. On the interior of the adjacent free ends, at or near the distal ends thereof, there are deposited on the interior surface of the glass tube, interior ring electrodes 34, 35 respectively. Thus, the exterior ring electrode 32 and the associated interior ring electrode 34 form one capacitative coupling to one end of the biaxial tube 28, and the exterior ring electrode 33 and its associated interior ring electrode 35 form a second capacitive coupling. Both of the exterior ring electrodes 32, 33 are energized by the RF power source 31. A field is created inside the tube 28, between interior electrodes 34, 35 which ionizes the gas inside the tube. Other configurations of capacitive-coupled electrodeless lamps as well as combinations employing both capacitative and inductive couplers are described in U.S. Pat. No. 5,300,860, the disclosure of which is incorporated herein by reference.
The exterior ring electrodes 32, 33 as well as the RF power source 31 and its associated power leads 35, which may be flexible, as described above, are embedded in an epoxy material, the envelope of which is diagrammatically illustrated at 36 similar to the one described above.
Turning now to FIG. 4, there is shown a cross section of one of the free ends of the tube 28. The glass envelope is designated 28D for one of the tube sections for the biaxial tube 28; the interior ring electrode is designated 34, and the exterior ring electrode is shown at 32 in FIG. 4, the epoxy covering again being shown at 38. It will be observed that the epoxy is formed into two cup-shaped receptacles or sockets for the free ends 28A, 28B of the biaxial fluorescent tube 28 so that it may be assembled to the combination of power lead, RF power source and exciting capacitor coupling, but be removed in the event that re-lamping is necessary.
Turning now to FIG. 5, there is shown a structure for housing a portable handlamp employing the construction of the present invention shown in FIG. 3. The flexible power cord is again designated 35, and it is coupled into a metal base 38 which is sized to be conveniently held in one hand. Housed within the base 38 would be the epoxy-encompassed RF power source 31 and the exterior ring electrodes 32, 33. The biaxial tube 28 is received in the sockets formed by the epoxy compound, and an exterior protective screen or gridwork, of metal, surrounds the tube 28, and is designated 42. The upper portion of the protective grid 42 is covered with a coventional metal cap 43 which may be provided with a convenience hanger 44. The grid 42 is formed from interconnected axial elements 46 and circumferential elements 47 to form an EMI suppression grid. The spacing of the elements of the grid 42 is related to the wavelength of the operating frequency (or harmonics) of RF source to suppress electromagnetic interference as desired according to principles well known to those skilled in the art. In this case, the metal grid forms not only a protective function for the lamp 28, but it also provides an electromagnetic interference shield.
In addition to those embodiments which have been illustrated, there are other configurations of glass envelopes as well as other excitation devices or couplers to which the invention is readily adaptable. For example, it is known that the glass envelope 10 for an electrodeless lamp may be in the form of a toroid, and the coupler may be in the form of a coil surrounding a portion of the toroid in a circumferential manner.
In order to re-lamp this type of fixture, the coupler is made into a split coil so that it may be removed from the lamp. In this case, the coupler may be designed so that each portion of the winding is fixed on a ferrite material of semi-toroidal shape, and conforming to the shape of the glass envelope when the two halves of the coupler are assembled. The RF power source for exciting the coupler may be conventional. This type of structure is sometimes referred to as a "tokomac" design, and a person skilled in the art will readily appreciate that the present invention may be modified and accommodated to it.
Still another modification is to extend the application to high-intensity discharge (HID) lamps. Electrodeless HID lamps are now commercially available.
Having thus disclosed in detail preferred embodiments of the invention, persons skilled in the art will be able to modify certain of the structures which has been illustrated and to substitute equivalent elements for those disclosed while continuing to practice the principle of the invention; and it is, therefore, intended that all such modifications and substitutions be covered as they are embraced within the spirit and scope of the appended claims. | A fluorescent lamp for use in special applications includes an electrodeless envelope of glass or other light transmissive material carrying fluorescent material within the envelope. An RF energy source and coupler are embedded in epoxy as an integral power unit, thereby isolating the power unit from the hazardous environment. The power unit and the envelope are shaped in complementary form such that the coupler and envelope are in energy-transfer relation to excite the lamp, but the envelope may be removed from the power unit to re-lamp the fixture. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method of removing organic-containing materials such as photoresists, high temperature organic layers, and organic dielectric materials from a substrate surface of a flat panel display or solar cell array or other large scale substrate (a substrate which is typically larger than about 0.5 meter by 0.5 meter).
2. Brief Description of the Background Art
The information in this Background Art portion of the application is provided so that the reader of the application can better understand the invention which is described subsequently. The presence of information in this Background Art portion of the application is not an admission that the information presented or a that a combination of the information presented is prior art to the invention.
The fabrication of electronic device structures is complicated by the number of different materials which are used, both to provide the elements of the functional device, and as temporary process structures during fabrication of the device. Since most of the devices involve the formation of layers of inter-related, intricate, patterned structures, photoresists and high temperature organic masking materials are commonly used during patterning of underlying layers of material which are present over large area (typically about 0.25 m 2 or greater) surfaces. A patterned photoresist is one of the temporary processing structures and must be removed once work on the underlying structure through openings in the photoresist is completed. Therefore, there is a need for an efficient and inexpensive method of removing, stripping, or cleaning of organic photoresists, as well as other organic layer residues, from large substrate surfaces. Due to the varying composition of a substrate underlying a photoresist, for example, it is important that a method used to remove the photoresist not be reactive with (corrosive to) surfaces underlying the photoresist. One problem has been the presence of metallic materials and the tendency of these materials to oxidize and dissolve the oxidized layer.
To be useful in processing of large surface areas, it is helpful to have the stripping and cleaning material be a non-corrosive fluid. The fluid should be minimally affected by the presence of an ambient atmospheric condition. It is also helpful when the removal process can be carried out at room temperature, or at least below about 80° C. Finally, it is always desirable that the fluid used for removal of the organic material be environmentally friendly.
In order to remove an organic material such as a photoresist for example, and specifically to strip photoresist from large substrate surfaces, a number of techniques have been used. Representative techniques for removing photoresists, as well as their advantages and disadvantages, are described below.
A Piranha solution, which consists of sulfuric acid (H 2 SO 4 ) and hydrogen peroxide (H 2 O 2 ), typically in a volumetric ratio of 4:1, works well for photoresist removal, but cannot be used on substrate surfaces which include exposed metal, because it will etch the metal. Also, because it is very viscous, the Piranha solution is difficult to rinse off a substrate surface after a photoresist removal process. Further, the H 2 SO 4 /H 2 O 2 solution cannot be recovered or re-used many times, as it decomposes rapidly. Finally, the solution needs to be applied at relatively high temperatures of at least 70° C., and typically about 120° C.
Several other techniques for removal of organic photoresists are based on the use of organic solvent-based strippers, such as monoethanolamine (MEA), dimethylsulfoxide (DMSO), n-methylpyrrolidone (NMP), propylene glycol monomethyl ether acetate (PGMEA), ethyl lactate, and methylethylketone (MEK). Unlike the Piranha solution, these organic solvent strippers can be used when metals are present. However, these organic solvent strippers cannot be easily recovered after saturation with dissolved photoresist, because the photoresist is difficult to separate from the organic solvent. Therefore, the saturated organic solvent strippers must be disposed of, creating an environmental problem, or recovered for recycling using a distillation technique which is cumbersome and expensive. Like the Piranha solution, these solvents are typically heated prior to use, but to somewhat lower temperatures than the Piranha solution, typically around 50-65° C.
Japanese Patent Publication No. 59125760, of Tanno et al., published Jan. 10, 1986, describes dissolving ozone in an organic acid (such as formic acid or acetic acid) and using the ozonated organic acid to remove contamination from semiconductor substrates. Any heavy metal on the wafer is said to form a formate or an acetate, and any organic contaminant is decomposed by ozone, so that stains on the surface of the substrate can be removed.
T. Ohmi et al., in an article entitled “Native Oxide Growth and Organic Impurity Removal on Si Surface with Ozone-Injected Ultrapure Water” ( J. Electrochem. Soc ., Vol. 140, No. 3, March 1993), describe the use of ozone-injected ultrapure water to remove adsorbed organic impurities from a wafer surface prior to other wafer cleaning procedures. Ozone concentration in the water was 1-2 ppm. The process described by Ohmi et al. was said to be capable of effectively removing organic contaminants from the wafer surface in a short time at room temperature. Processing waste from the process was said to be simple, and the chemical composition of the ozone-injected ultrapure water was said to be easily controllable.
U.S. Pat. No. 5,464,480, issued Nov. 7, 1995, to Matthews et al., and entitled “Process and Apparatus for the Treatment of Semiconductor Wafers in a Fluid”, describes a process for removing organic materials from semiconductor wafers using chilled deionized water (1° C. -15° C.). The amount of ozone dissolved in the water is temperature-dependent. Lowering the temperature of the water is said to have increased the concentration of ozone in the water and to have increased the photoresist strip rate using the ozone/chilled water solution.
U.S. Pat. No. 5,632,847, issued May 27, 1997, to Ohno et al., and entitled “Film Removing Method and Film Removing Agent”, describes a method of removing a film (e.g., an organic or metal-contaminated film) from a substrate surface by injecting ozone into an inorganic acid aqueous solution (e.g., a mixed solution of dilute HF and dilute HCl) and bringing bubbles formed by the ozone injection into direct contact with the film. Each bubble is said to be composed of an inside ozone bubble and an outside acid aqueous solution bubble. The Ohno et al. reference recommends an acid aqueous solution of 5 weight % or less, kept at room temperature, where the ozone concentration is within a range from 40,000 ppm to 90,000 ppm. Ozone has also been dissolved in sulfuric acid for use in cleaning semiconductor surfaces, as described, for example, in U.S. Pat. Nos. 4,917,123 and 5,082,518.
U.S. Pat. No. 5,690,747, issued Nov. 25, 1997, to Doscher, and entitled “Method for Removing Photoresist with Solvent and Ultrasonic Agitation”, describes a method for removing photoresist using liquid organic solvents which include at least one polar compound having at least one strongly electronegative oxygen (such as ethylene diacetate) and at least one alicyclic carbonate (such as ethylene carbonate).
European Patent Publication No. 0867924, of Stefan DeGendt et al., published Sep. 30, 1998, and entitled “Method for Removing Organic Contaminants from a Substrate”, describes the use of an agent to remove the organic contaminants, where the agent comprises water vapor, ozone, and an additive acting as a scavenger. Use of a liquid agent comprising water, ozone, and an additive acting as a scavenger is also discussed. The additive is recommended to be an OH radical scavenger, such as a carboxylic or phosphoric acid or a salt thereof. Preferred examples are acetic acid and acetate, as well as carbonate and phosphate. Although carboxylic acids as a whole are mentioned, there is no data for any carboxylic acid other than acetic acid. The authors describe how the ozone level of an aqueous ozone solution increases upon the addition of acetic acid to the water-based solution. They also disclose that photoresist strip rate increases upon the addition of acetic acid to an aqueous ozone solution. This publication is incorporated by reference in its entirety.
U.S. Pat. No. 6,080,531, issued Jun. 27, 2000, to Carter et al., and entitled “Organic Removal Process” describes a method of photoresist removal in which a treating solution of ozone and bicarbonate (or other suitable radical scavenger) is used to treat a substrate for use in an electronic device. The concentration of bicarbonate ion or carbonate ion in the treating solution is said to be approximately equal to or greater than the ozone concentration. The method is said to be suited to removal of photoresist (as well as other organic materials) where metals such as aluminum, copper, and their oxides are present on the substrate surface.
Japanese Patent Publication No. 2002/025971, published Jan. 25, 2002, and assigned to Seiko Epson Corp. and Sumitomo Precision Prod. Co., teaches the use of ozonated water with acetic acid and ultraviolet radiation to remove photoresist. Ozonated water containing acetic acid is continuously supplied to the center portion of a rotating substrate. The ultraviolet rays from a UV lamp are irradiated onto the substrate to remove resist adhering to the surface of the substrate. The process is said to remove organic substances such as resist adhering onto the substrate without need for high temperature heat treatment.
U.S. Patent Application Publication No. 2002/0066717 A1, of Verhaverbeke et al., published Jun. 6, 2002, and entitled “Apparatus for Providing Ozonated Process Fluid and Methods for Using Same”, describes apparatus and methods for wet processing of electronic components using ozonated process fluids. Verhaverbeke et al. teach that it is desirable to have as high an ozone concentration as possible to achieve rapid cleaning of electronic components. Verhaverbeke et al. achieved ozone concentrations in water up to 300 g/m 3 by using a closed vessel with recirculated ozonated liquid, which is supplied under pressure. Verhaverbeke et al. describe the use of various chemically reactive process fluids which may be used in combination with ozone, including inorganic acids, inorganic bases, fluorinated compounds, and acetic acid. The Verhaverbeke et al. reference also provides an overview of the literature on the use of ozonated deionized water for photoresist removal from electronic component surfaces. This published patent application is incorporated by reference in its entirety.
U.S. Patent Publication No. 2002/0173156 A1, of Yates et al., published Nov. 21, 2002, and entitled “Removal of Organic Material in Integrated Circuit Fabrication Using Ozonated Organic Acid Solutions”, describes the use of organic acid components to increase the solubility of ozone in aqueous solutions which are used for removing organic materials, such as polymeric resist or post-etch residues, from the surface of an integrated circuit device during fabrication. Each organic acid component is preferably said to be chosen for its metal-passivating effect. Such solutions are said to have significantly lower corrosion rates when compared to ozonated aqueous solutions using common inorganic acids for ozone solubility enhancement, due to a surface passivating effect of the organic acid component.
U.S. Pat. No. 6,551,409, issued Apr. 22, 2003, to DeGendt et al., and entitled “Method of Removing Organic Contaminants from a Semiconductor Surface”, describes a method for removing organic contaminants from a semiconductor surface, where the semiconductor is held in a tank which is filled with a gas mixture comprising water vapor and ozone. DeGendt et al. teach that the use of gas phase processing, where the substrate surface is contacted with an ozone/water vapor mixture, enables an increase in ozone concentration near the wafer surface.
U.S. Pat. No. 6,674,054, issued Jan. 6, 2004, to Boyers et al., and entitled “Method and Apparatus for Heating a Gas—Solvent Solution”, describes a method of quickly heating a gas—solvent solution from a relatively low temperature T 1 to a relatively high temperature T 2 , such that the dissolved gas concentration at T 2 is much higher than if the gas had originally been dissolved into the solvent at T 2 . The example of gas—solvent solution is an ozone gas in water solution. The objective is to heat a cold ozone—water solution using an in-line heater just prior to application of the solution to a substrate surface, to increase the reaction rate at the substrate surface. Table A in Col. 33 shows the solubility of ozone gas in water as a function of temperature and pressure. This '054 patent is incorporated by reference in its entirety.
U.S. Pat. No. 6,696,228, issued Feb. 4, 2004, to Muraoka et al., and entitled “Method and Apparatus for Removing Organic Films”, describes a method and apparatus for removing an organic film such as a resist film from a substrate surface using a treatment liquid which can be recycled and re-used. The treatment liquid is typically formed from liquid ethylene carbonate, liquid propylene carbonate, or a mixture thereof, and typically contains dissolved ozone. Since ethylene carbonate is a solid at room temperature, this photoresist removal method requires the use of elevated temperatures, in the range of about 50-120° C.
U.S. Pat. No. 6,699,330, issued Mar. 2, 2004, to Muraoka, and entitled “Method of Removing Contamination Adhered to Surfaces and Apparatus Used Therefor”, describes a method of removing surface-deposited contaminants from substrates for electronic devices. The method includes bringing an ozone-containing treating solution into contact with the surface of a treating target (such as a semiconductor substrate) on which contaminants have deposited. The ozone-containing treating solution comprises an organic solvent having a partition coefficient to ozone of 0.6 or more, where the partition coefficient refers to a partition or division of gaseous ozone between an organic solvent that is in a liquid phase at standard temperature and pressure and an inert gas in a gaseous phase which comes in contact with the organic solvent. Any organic solvents are said to be useful in the invention, so long as they provide the desired partition coefficient. Preferably organic solvents are fatty acids, including acetic acid, propionic acid, and butyric acid. Enabling embodiments are provided for acetic acid. Ozonated acetic acid is used in a closed system with a constant ozone partial pressure above the system to keep a high concentration of ozone in the acetic acid and to minimize evaporation of the acetic acid.
Although high concentrations (≧200 ppm) of ozone can be obtained in acetic acid, and ozonated acetic acid may provide a rapid photoresist strip rate (≧1 μm/min), there are major drawbacks to the use of ozonated acetic acid for photoresist removal. One of the primary considerations is corrosivity. The presence of acetic acid has been observed to cause corrosion in metals, in particular, copper and molybdenum. These metals are commonly used in the flat panel display industry. Further, acetic acid is a solid at temperatures below about 16.7° C., which can cause problems under some desired processing conditions.
In view of the above, there is a need for an improved method of stripping and cleaning organic materials from electronic device surfaces, particularly when metals are present. In particular, there is a need for a stripping and cleaning method which has universal applicability with respect to the surface composition of the substrate. Due to the common presence of metals in semiconductor device substrates, flat panel display substrates, and solar cell arrays, methods of stripping and cleaning organic materials which are harmful when metals are present are not attractive.
Further, with respect to the manufacture of large flat panel substrates (such as those used for AMLCD or AMOLED panels, and in some instances solar panels), there is a need for a stripping and cleaning solution that can be applied over a stationary object or on an object that is moving on a conveyor belt in an atmospherically exhausted environment.
In addition, it would be highly desirable if the stripping and cleaning solution could be re-used over multiple processing cycles, without the need for frequent replenishment or filtering of the solution. It would also be advantageous if such an improved method for the removal of organic materials could be performed at room temperature.
SUMMARY OF THE INVENTION
Described herein is method of removing an organic-containing material from an exposed surface of a large substrate (at least 0.25 m 2 ). The exposed surface of the substrate may comprise an electronic device. The exposed surface is treated with a stripping solution comprising ozone (O 3 ) in a solvent, where the solvent comprises acetic anhydride. The method has a number of advantages, including but not limited to the following: A rapid organic material removal rate of at least 0.5 μm/min, and typically greater than about 2 μm/min is typically obtained. Low corrosivity with respect to metals such as copper, molybdenum, and tungsten is observed, where the corrosion rate has been observed at about 1 nm/min. for copper, to 0.6 nm/min. for molybdenum, to 0 nm/min. for tungsten. The reagent solution (“stripping solution’) used to remove the organic-containing material is designed to avoid or minimize reactivity with metals to any extent which affects the overall electronic performance of the metal after the stripping process. The stripping process can be performed at room temperature (about 25° C.) if desired. Further, the stripping process may be performed in an atmospheric pressure exhausted system, if desired, in view of the volatility of the stripping solution. The stripping solution can be recycled over multiple processing cycles, so that it needs to be refreshed only about every 24 hours, or longer. In addition, the stripping solution is easily cleaned off the substrate surface using a water rinse.
The stripping solution comprises ozone (O 3 ) in a solvent, where the solvent comprises acetic anhydride. The stripping solvent used to form the stripping solution may comprise a mixture of acetic anhydride with a co-solvent selected from the group consisting of a carbonate containing 2-4 carbon atoms, ethylene glycol diacetate, and combinations thereof. In some instances, the stripping solution may contain only acetic anhydride and ozone, where the ozone concentration is typically about 300 ppm or greater. When a co-solvent is used, the stripping solution comprises acetic anhydride, ozone, and a co-solvent which may be present at a concentration ranging from about 20% by volume to about 80% by by volume of the stripping solution. When the co-solvent is a mixture of a carbonate with ethylene glycol diacetate, the ratio of carbonate to ethylene glycol diacetate may range from about 1:1 up to about 3:1.
The method of the invention may be used to strip organic materials from the surface of a substrate without concern that an exposed metal will be harmed in a manner which substantially affects the performance of a device which relies on performance of the metal.
The concentration of ozone in the stripping solution typically ranges from about 50 ppm to about 600 ppm; more typically from about 100 ppm to about 500 ppm; and often from about 300 ppm to about 500 ppm. If the stripping solution contains too little ozone, the organic material removal rate will be unacceptably slow. With minimal experimentation, one skilled in the art will be able to determine an appropriate ozone concentration, based on the composition of the substrate surface. Because the solubility of ozone in an acetic anhydride-containing stripping solution increases as the concentration of acetic anhydride increases, the concentration of acetic anhydride in the stripping solution is often the maximum possible, depending on the composition of the substrate beneath the organic material which is being removed. When the stripping solution includes a co-solvent with the acetic anhydride, the co-solvent must not react with the acetic anhydride or the substrate beneath the organic material. Co-solvents which work particularly well include ethylene carbonate and ethylene glycol diacetate.
When the stripping solution comprises acetic anhydride with at least one co-solvent of the kind described above, the concentration of ozone in the stripping solution typically ranges from about 50 ppm to about 300 ppm.
Pure acetic anhydride exhibits a vapor pressure of about 500 Pa at 20° C. An acetic anhydride-comprising stripping solvent typically exhibits a vapor pressure within the range of about 100 Pa to about 600 Pa; more typically, from about 100 Pa to about 500 Pa.
Acetic anhydride exhibits a vapor pressure which is about one third that of acetic acid at 20° C. As a result, there is a much more mild odor when acetic anhydride is used as a stripping solvent than when acetic acid is used as a stripping solvent. An anhydride-comprising stripping solvent can be used in an atmospheric pressure exhausted environment.
Acetic anhydride is a liquid at standard temperature (25° C.) and pressure, since the melting point of acetic anhydride is approximately −73° C. As a result, the problems which may occur when acetic acid is used as a stripping solvent (acetic acid has a melting point of about 16.7° C. at standard pressure) do not occur when acetic anhydride is used as a stripping solvent. Since the solubility of ozone in acetic anhydride is essentially the same as the solubility in acetic acid, there are definite advantages to using acetic anhydride as the principal ingredient in a stripping solvent. Use of an acetic anhydride-comprising stripping solvent at room temperature is advantageous. When pure acetic anhydride is used as the solvent portion of the stripping solvent, the recommended temperature range for removing organic materials from the substrate ranges from about 15° C. to about 80° C. More typically, the stripping temperature will be the range of about 20° C. to about 40° C.
The recommended temperature ranges are based on a combination of factors, including the time required for stripping and cleaning (removal) of the organic material and the decomposition rate of the organic material which is being stripped in the stripping solution, the volatility of the stripping solution, and the melting points of the ingredients of the stripping solution. When the stripping solvent comprises acetic anhydride in combination with about 20% by volume to about 80% by volume of one of a carbonate containing from 2 to 4 carbons (such as ethylene carbonate), ethylene glycol diacetate, or a combination thereof, a typical temperature range for removal of the organic material from the substrate is about 15° C. to about 80° C. In one typical embodiment, the stripping solvent comprises about 20% by volume acetic anhydride, about 40% by volume ethylene carbonate, and about 40% by volume ethylene glycol diacetate. One skilled in the art will be able to optimize the stripping temperature range for a specific application after minimal experimentation based on the present disclosure.
Since organic compounds actually decompose (rather than just dissolve) in ozonated anhydride stripping solutions, the stripping solution can be re-used over multiple processing cycles. The number of cycles for which the stripping solution can be re-used will depend on the maximum concentration of organic material residue which is tolerable in the stripping and cleaning solution. Typically a production line for stripping organic materials from a substrate can be operated for at least one day without the need to refresh the stripping solution.
The addition of a carbonate, or ethylene glycol diacetate, or a combination of these co-solvents to an acetic anhydride/ozone stripping solution both reduces the odor of the stripping solution and the minor corrosivity exhibited by the anhydride-comprising stripping solution. However, the solubility of ozone in the stripping solution is reduced by the co-solvent.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings which follow may be used in combination with the detailed description to aid in understanding of the invention. Identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.
FIG. 1 is a graph showing the concentration of dissolved ozone (in mg/L i.e. ppm) as a function of deionized water temperature (in ° C.), when the water surface is in contact with ozone gas in oxygen at a concentration of 240 mg/L.
FIG. 2A shows a schematic of one embodiment of an organic material stripping system of the kind which can be used to process large substrate in a relatively open, vented system. The stripping solution is sprayed onto a substrate surface as the substrate moves along a conveyor.
FIG. 2B is a schematic showing an interior view of enclosed stripping area 204 of FIG. 2A , with a large flat panel display substrate, such as a glass-comprising substrate 210 , passing under an overhead stripping solution supply conduit 213 . The stripping solution is applied by spray 215 from spray nozzles 214 .
FIG. 3 is a schematic of an exemplary stripping solution preparation system 300 , where an anhydride-comprising solvent is ozonated, to provide an ozonated anhydride-comprising stripping solution.
FIG. 4A is a simplified schematic of a bubbler apparatus which can be used to generate vaporous ozonated anhydride-comprising stripping solution from a liquid ozonated anhydride-comprising stripping solution of the kind produced by the preparation system 300 shown in FIG. 3 .
FIG. 4B is a schematic showing a nozzle 412 scanning over the surface 405 of a substrate 406 which is a rotating wafer. This is an embodiment method of applying a stripping solution over a substrate surface, where the anhydride-comprising stripping solution is in vapor form 407 as it exits nozzle 412 .
FIG. 4C is a schematic showing a vapor distribution plate 430 used in combination with a bubbler 424 which generates a vapor form of an anhydride-comprising stripping solution. The vapor distribution plate 430 distributes the stripping vapor 432 evenly over a substrate 434 surface 433 .
FIG. 5A is a schematic front-view of an alternative embodiment system 500 for applying either a liquid stripping solution or a liquid rinse for removing stripping solution residue to a substrate 504 surface 502 . The liquid is sprayed 508 upon the surface 502 as the substrate 504 moves past a spray applicator 506 .
FIG. 5B is a schematic side view of the alternative embodiment system shown in FIG. 5A . The substrate 504 is positioned at an angle θ from horizontal, so that spray 508 from spray applicator 506 will be pulled toward the bottom of substrate 504 , using gravity assist to remove the liquid stripping solution or liquid rinse.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
As a preface to the detailed description presented below, it should be noted that, as used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include plural referents, unless the context clearly dictates otherwise. The term “about”, as used herein, refers to a value or range which may encompass plus or minus 10% of a particular cited value or range.
FIG. 1 is a graph 100 showing the concentration on axis 102 of dissolved ozone in deionized (DI) water (in mg/L, i.e. in ppm) a function of the (DI) water temperature shown on axis 104 , when the DI water surface is in contact with ozone gas at a concentration of 240 mg/L in oxygen. It is readily apparent that the solubility of ozone in deionized water at room temperature (approximately 25° C.) is only about 40 mg/L. This requires the use of chilled (below room temperature) temperatures when a stripping solution of dissolved ozone in DI water is used, just to obtain a more helpful ozone concentration in the stripping solution.
Ozone concentration in deionized water, acetic acid, and acetic anhydride solvents, where the solvent temperature is 19° C., and the solvent surface is in contact with ozone in oxygen at a concentration of about 240 mg/L at 19° C. is presented in Table One, below.
TABLE ONE
Ozone Concentration in Various Solvents at 19° C.
Dissolved O 3 Concentration
Solvent
(mg/L)
DI Water
55
Acetic Acid
503
Acetic Anhydride
503
As described in several of the publications referenced in the “Brief Description of the Background Art” section above, the concentration of ozone in an aqueous solution can be increased by adding acetic acid to the solution. Ozone can also be dissolved in pure acetic acid. Ozone dissolved in acetic acid or formic acid can be used to remove organic contamination and to strip photoresist from electronic device substrates. However, as previously discussed, acetic acid and formic acid are corrosive with respect to metals such as copper and molybdenum, which are used in flat panel display electronic elements. Copper and molybdenum are often present at the surface of a substrate at the time it is desired to remove an organic material from the surface of the substrate.
The use of an acetic anhydride solvent rather than an acetic acid solvent makes it possible to reduce the corrosion of copper and molybdenum by a surprising amount. Table Two below shows a comparison of metal corrosion rates for copper, molybdenum and tungsten when exposed to a stripping solution of ozone in acetic acid, compared with a stripping solution of ozone in acetic anhydride. The concentration of ozone present in each solution was 300 mg/L and the exposure temperature was 20° C., with an exposure time period of one minute.
TABLE TWO
Metal Corrosion Rates in Ozone Solutions, in nm/min
Copper
Molybdenum
Tungsten
Corrosion Rate
Corrosion Rate
Corrosion Rate
Stripping Solvent
(nm/min.)
(nm/min.)
(nm/min.)
Acetic Acid/Ozone
20
4
0
Acetic Anhydride/
1
0.6
0
Ozone
Clearly, there is a surprising reduction in the corrosion rate when the ozonated acetic acid stripping solvent is replaced by an ozonated acetic anhydride stripping solvent. This difference in corrosion rate enables a more complete removal of an overlying organic material while maintaining the performance capability of a metal-comprising device structure which is exposed on the surface of a substrate from which the overlying organic material is being removed.
Table Three below illustrates other important physical property differences between acetic acid and acetic anhydride which show that acetic anhydride is a preferred stripping solvent when compared with acetic acid.
TABLE THREE
Physical Property Comparison, Acetic Acid and Acetic Anhydride
Physical Property
Acetic Acid
Acetic Anhydride
Vapor Pressure
11
3.75
(mm Hg at 20° C.)
Flash Point (° C.)
40
54
Melting Point (° C.)
16.7
−73
Boiling Point (° C.)
118
139
Table Three shows a lower vapor pressure for acetic anhydride. This helps to reduce odor in the workplace attributable to presence of the stripping solvent. The higher flash point of acetic anhydride reduces the fire danger when acetic anhydride/ozone is used as the stripping solvent. The lower melting point of acetic anhydride ensures that the stripping solvent will remain a liquid under the conditions at which it is used.
Ozonated acetic anhydride, at an ozone concentration of about 300 mg/L, when used as a liquid stripping agent at about 20° C., can remove 1 μm of photoresist from the surface of a semiconductor substrate (of the kind used to produce flat panel displays) in a time period of 60 seconds. Since organic compounds, including photoresists, typically decompose (rather than just dissolve) in ozonated solutions comprising acetic anhydride, a considerable amount of the decomposition products are volatilized and easily removed. As a result, the stripping solution can be recycled for re-use over multiple processing cycles. The number of cycles for which the stripping solution can be re-used will depend on the maximum concentration of organic material residue which is tolerable in the stripping and cleaning solution. Distilled water or deionized water is frequently used to wash off residual stripping solution from a substrate surface. Other solvents may be used to wash off residual stripping solution, depending on ease of handling in a particular application, and it is not intended that deionized water be the only rinse solution which may be used.
However, since acetic anhydride is converted to acetic acid when exposed to water, use of a water rinse to remove residual ozonated anhydride-comprising stripping solution from the semiconductor substrate is easy. The required rinse time, using a sprayed-on rinse solution, is in the range of about 30 seconds; and, the rinse can be easily processed to remove dissolved organic materials, with the acetic acid being recovered from the rinse if desired.
The corrosiveness and volatility of acetic anhydride, can be further reduced by mixing the anhydride with another organic solvent which is even less corrosive. The other non-corrosive organic solvent should be non-reactive with ozone and should exhibit a volatility which is typically less than about 30% higher than the volatility of acetic anhydride. Solvents which are non-corrosive to metals, which have little or no reactivity with ozone, which exhibit very limited reactivity with anhydrides, which are soluble in acetic anhydride, and which are liquid at room temperature when mixed with the anhydride are most desirable. Solvents which meet these criteria include (for example and not by way of limitation) ethylene carbonate, propylene carbonate, and ethylene glycol diacetate.
Ethylene carbonate is a colorless, odorless solid with a flashpoint of 143.7° C. and a freezing point of 36.4° C. In its pure state, ethylene carbonate is a solid at room temperature. Ethylene carbonate is non-reactive to ozone, non-corrosive to metals, and is miscible in acetic anhydride.
Like ethylene carbonate, propylene carbonate is odorless and colorless. Propylene carbonate is a liquid at room temperature. The disadvantage of propylene carbonate is that it is less soluble in water than ethylene carbonate, and thus it is more difficult to rinse residual propylene carbonate off a stripped substrate surface.
Like ethylene carbonate and propylene carbonate, ethylene glycol diacetate is colorless and low in odor. Ethylene glycol diacetate is a liquid at room temperature.
The solubility of ozone in ethylene carbonate or propylene carbonate is considerably less than the solubility of ozone in acetic anhydride (about 40 ppm ozone in ethylene carbonate, as opposed to roughly 500 ppm ozone in acetic anhydride, at 20° C.). Because of this decrease in ozone solubility, addition of a carbonate to the stripping solution would be used only when the substrate from which the organic material is being stripped is particularly sensitive to corrosion by the stripping solution.
To provide an acceptable organic material removal rate and to maximize corrosion protection, a balance must be achieved between the concentration of the acetic anhydride and the concentration of a co-solvent used in the stripping solution. Typically, the carbonate co-solvent containing from 2 to 4 carbons is added in an amount so that the stripping solvent comprises between about 10 and about 90 volume % of this co-solvent; more typically, the carbonate comprises between about 20 and about 70 volume % of the stripping solvent; and often the carbonate comprises between about 30 and about 40 volume %, of the solvent.
The present method of removing organic-containing material can be performed in a simple atmospheric pressure exhausted environment, since a solvent comprising anhydride, alone or in combination with a co-solvent of the kind described above is not particularly volatile or offensive in odor at temperatures of about 40° C. or lower. Due to their relatively low volatility of acetic anhydride and the co-solvents mentioned herein, the ozonated stripping solution can be sprayed without excessive evaporation, and in most instances can be applied at room temperature, which is typically far below the flammability point of acetic anhydride, as previously mentioned.
Ideally, the ozone will decompose or oxidize the organic material completely to CO 2 or a carboxylic acid, which then is either vented through an exhaust system or is retained within the solvent. However, minimal quantities of non-oxidizable organic material components may remain after an organic material removal process. These non-oxidizable components will eventually begin to build up in the stripping solution comprising acetic anhydride and ozone. Solid contaminants which remain in the stripping solution upon recycling can be filtered out of the solution. From time to time (possibly only once a day, or even longer in most instances, depending on the solvent system), the stripping solution may need to be refreshed to flush out any residues which are accumulating. Organic residues may be removed using a “bleed-and-feed” process of the kind known in the art.
Ozonated acetic anhydride-comprising stripping solution is very easily removed from the substrate by rinsing with deionized water, as previously described, because the acetic anhydride is converted to acetic acid, which is completely miscible with water. Following an organic-containing material removal process, a final treatment with deionized water or ozonated deionized water can be used to rinse off the residual stripping solution. The ozonated deionized water is used only when there is no corrosion problem on the surface of the substrate. The ozonated deionized water is helpful in removing any residual organic materials on the substrate surface which contain single carbon-to-carbon bonds. In one embodiment of the method, a substrate surface is first sprayed with a liquid ozonated acetic anhydride-comprising stripping solution, to remove organic material from the substrate surface, followed by a second spraying with a liquid ozonated deionized water to remove any remaining organics, and to rinse off the ozonated stripping solution. Optionally, a final step may be used, in which deionized water is used to remove residue from the first rinse.
In another embodiment of the present method, the stripping solvent is applied to the substrate surface as a vapor (rather than as a liquid). In the case of vapor application, the use of pure acetic anhydride/ozone stripping solution (as opposed to use of a co-solvent ) simplifies recycling of the stripping solution. One skilled in the art will recognize that use of a combination of ingredients typically causes the vapor concentration to be different than the liquid concentration. Typically, the volatilizing temperature of the solvent is within a range of about 20° C. to about 150° C. The solvent vapor is brought into contact with the substrate to be stripped of organic-containing material. The solvent vapor may then be condensed on the substrate surface, leaving a layer of condensed stripping solvent on the substrate surface, followed by contacting the condensed layer with ozone gas. The ozone dissolves into the stripping solvent to form a condensed layer of ozonated acetic anhydride-comprising stripping solution that will remove the organic-containing material.
In another embodiment, ozone gas may be used as a carrier gas to bring vaporized acetic anhydride-comprising solvent to the workpiece surface. In this instance, the stripping solvent is more easily a combination of ingredients, as long as these ingredients can be entrained in the ozone carrier gas, to provide an ozonated stripping solution at the substrate surface.
I. APPARATUS FOR PRACTICING THE INVENTION
FIG. 2A shows one apparatus embodiment which may be used for stripping of organic-comprising materials from the surface of large flat panels of the kind used for flat panel display products. The apparatus 200 makes use of a spray application of stripping solvent to the surface of the substrate from which the organic-comprising material is to be removed. The apparatus illustrated in FIG. 2A is useful for processing substrates which may be as large as several meters in width and length. The processing environment is open at the entry conveyor location 202 and is exhausted in areas where the stripping solvent is applied, such as in enclosed stripping area 204 . FIG. 2A shows a stripping apparatus 200 where a substrate (not shown) is loaded onto an open entry conveyor 202 , and enters into an enclosed stripping area 204 through an opening 206 at the leading end 208 of the enclosed stripping area. The substrate enters enclosed (and exhausted, not shown) stripping area 204 , where stripping solvent (not shown)is applied from supply 201 through conduits 203 . FIG. 2B shows a close-up schematic of the interior of enclosed stripping area 204 , in which a flat panel substrate 210 is moving across conveying rollers 212 , while stripping solution 215 is sprayed onto the surface 216 of substrate 210 through spray nozzles 214 . The spray nozzles 214 are arranged so that the entire surface 216 of the substrate 210 will be uniformly coated with the stripping solution.
After application of the stripping solution 215 , the substrate passes into enclosed area 205 where a rinse (not shown) is used to wash off residual stripping solvent from the substrate. The rinse may be applied in a manner similar to that shown for the stripping solvent in FIG. 2B . After application of the rinse to the substrate surface, the substrate is passed into a drying area 207 , where the substrate is dried in a manner known in the art, such as by the application of gas flow across the substrate surface, use of heating lamps, or other commonly known techniques. After drying of the substrate, the substrate passes onto exit conveyor 209 for further handling.
FIG. 3 is a schematic of an exemplary apparatus 300 for the preparation of an ozonated acetic anhydride-comprising stripping solution. The ozonated acetic anhydride-comprising stripping solution may be supplied to a spray dispenser (such as that shown in FIG. 2B ), by way of example and not by way of limitation. The ozone used for ozonation of a stripping solution which comprises acetic anhydride is typically generated in an ozone generator 304 which is supplied by an oxygen source 302 (which may provide O 2 or air). The ozone is generated by applying a silent discharge (a discharge between 2 electrodes which is not self sustaining) to the oxygen or air, to produce an ozone containing gas . The ozone-containing gas is supplied to a solution preparation tank 314 through line 310 , which feeds a sparger/mixer 316 which dispenses ozone into a liquid acetic acid-comprising solvent (not shown) which is present in solution preparation tank 314 . Also included in the ozonated acetic anhydride-comprising stripping solution preparation apparatus 300 are (for example, and not by way of limitation) an acetic anhydride supply system, which may supply acetic anhydride and other co-solvents (not shown).
In one embodiment, by way of example and not by way of limitation, acetic anhydride in liquid form is fed, from line 306 and a co-solvent of the kind previously described is fed from line 308 , respectively, into a common line 312 which feeds into stripping solution supply tank 314 . When stripping solution supply tank 314 is not being filled, acetic anhydride from line 306 may be fed into common line 312 , and from there to common line 322 and into line 324 , which may be used to feed a stripping apparatus (not shown) in a process which makes use of acetic anhydride stripping solvent which is not ozonated. Common line 322 may also be used to drain residual ozonated acetic anhydride-comprising solution from solution preparation tank 314 through drain line 326 . The system may optionally include additional solvent supply apparatus (not shown) for optional co-solvents to be used in combination with an anhydride stripping solvent (such optional solvents may be a carbonate containing from 2-4 carbons, or ethylene glycol diacetate, as previously discussed, by way of example and not by way of limitation).
As previously discussed, the acetic anhydride-comprising stripping solution may alternatively be applied to a substrate surface in the form of a vapor. FIG. 4A is a simplified schematic of a bubbler apparatus 400 which can be used to prepare and apply a vaporous acetic anhydride-comprising stripping solution to a substrate 406 surface 405 . For example (and not by way of limitation), a solution 403 comprising acetic anhydride (and potentially other optional solvents in admixture with the acetic anhydride) in a tank 402 is heated using heater 404 . Ozone gas is supplied to tank 402 through an ozone intake 408 . Vaporous ozonated acetic anhydride-comprising stripping solution 407 is supplied through line 410 and nozzle 412 to the surface 405 of a substrate 406 . The temperature of the vaporous ozone saturated acetic anhydride-comprising stripping solution 407 is kept higher than the temperature of the wafer 406 surface 405 . Ozone-saturated acetic anhydride-comprising stripping solution vapor 407 condenses on the cooler surface 405 of substrate 406 . To increase mass transfer of ozone at to the substrate surface 405 , fresh ozone is continuously introduced into the acetic anhydride-comprising solution 403 in tank 402 . The layer of stripping solution (not shown) on the substrate surface 405 is very thin, so that ozone diffuses through the layer rapidly.
FIG. 4B is an illustration of the application of the vaporous stripping solution 407 , where an application nozzle 412 (for example and not by way of limitation, as several nozzles may be used) is scanned over the surface 405 of substrate 406 . The substrate is typically rotated as shown by arrow 414 in FIG. 4A , to aid in distributing the constant feed of condensing ozonated anhydride-comprising stripping solvent (not shown) over substrate surface 405 .
FIG. 4C shows a simplified schematic of another vaporous stripping solvent application apparatus 420 , where ozone is fed through ozone intake line 422 into a bubbler tank 424 containing at least one anhydride solvent (and potentially other co-solvents) 423 . The ozonated solvent present in bubbler tank 424 is heated using heater 426 to produce a vapor which is fed through a line 428 into a distribution plate 430 , from which stripping vapor 432 is dispensed onto a flat panel substrate 434 which is moving under distribution plate 430 in the manner shown, on a conveyor (not shown). The vapor condenses on substrate 434 surface 433 to produce a condensed stripping solvent 435 on the surface 433 of substrate 434 . One skilled in the art will recognize that the substrate 430 could be stationary, with the distribution plate 430 moving past the substrate 430 .
II. EXAMPLES
Example One
Removal of Photoresist from a Substrate Surface Using Ozonated Acetic Anhydride
A layer of a deep ultra-violet (DUV) photoresist which is sensitive to 248 nm radiation (UV 6, available from Shipley, Marlborough, Mass.) was applied to a thickness of approximately 10,000 Å (1,000 nm) onto the surface of a single-crystal silicon wafer. The photoresist was applied using a spin-on process, then baked for 30 minutes at 95° C. Ozonated acetic anhydride (100% acetic anhydride) stripping solution containing about 300 ppm (mg/L) of ozone was sprayed onto the surface of the photoresist-coated substrate at room temperature (25° C.) using a dispensing system such as that shown in FIG. 2B . The ozonated acetic anhydride was allowed to react with the photoresist for a period of 30, 60, or 120 seconds, then rinsed off the substrate surface by spraying with deionized water for a period of 10 to 20 seconds.
A series of six substrate samples were tested, where 1 μm of photoresist was present on each substrate, and the exposure time to stripping solution was varied from 30 seconds to about 120 seconds. Subsequent to the photoresist stripping procedure, each sample was examined and measured for residual photoresist. It was discovered that the 1 μm of photoresist was removed after 30 seconds (or less) from all of the substrates.
Example Two
Corrosivity of Ozonated Acetic Anhydride on Aluminum
A layer of aluminum was deposited to a thickness of about 10,000 Å onto the surface of a single-crystal silicon wafer using a physical vapor deposition (PVD) process of the kind known in the art. To test the corrosivity of ozonated acetic anhydride stripping solution on aluminum, ozonated acetic anhydride (100% acetic anhydride) stripping solution containing about 300 ppm (or mg/L) of ozone was sprayed onto the surface of the aluminum-coated substrate at room temperature (25° C.) using a dispensing system such as that shown in FIG. 2B . The ozonated acetic anhydride stripping solution was allowed to react with the aluminum for a period of 30, 60, or 120 seconds, then rinsed off the substrate surface by spraying with deionized water for a period of 10 to 20 seconds.
Within the accuracy of our ability to measure, aluminum was not removed by the ozonated acetic anhydride stripping solution. There appears to be a slight increase in the thickness of the aluminum layer, but the amount of increase in inconsistent with time. The increase in thickness of the aluminum layer may be due to the formation of Al 2 O 3 on the surface of the aluminum layer due to exposure to O 3 . However, the amount of change in aluminum thickness due to exposure to the stripping solution is so minor, less than 0.3 percent, that it may be within experimental error of the method of measurement. This indicates virtually no corrosion of the aluminum over a 120 second exposure time to the stripping solution. In the event it is determined that any significant amount of aluminum oxide is formed, one skilled in the art may use techniques known in the art to treat the surface of the substrate to remove oxide to the extent necessary to permit device function in the end use application.
Example Three
Corrosivity of Ozonated Acetic Anhydride a Copper Surface
A layer of copper was deposited to a thickness of 8,000 Å (800 nm) to 19,000 Å (1,900 nm) onto the surface of a single-crystal silicon wafer. The copper was deposited using a physical vapor deposition (PVD) process, followed by electrochemical plating. In order to test the corrosivity of ozonated acetic anhydride stripping solution on copper, ozonated acetic anhydride (100% acetic anhydride) containing at least 300 ppm (or mg/L) of ozone was sprayed onto the surface of the copper-coated substrate at room temperature (25° C.) using a dispensing system such as that shown in FIG. 2B . The ozonated acetic anhydride stripping solution was allowed to react with the copper surface for a period of 30, 60, or 120 seconds, then rinsed off the substrate surface by spraying with deionized water for a period of 10 to 20 seconds.
Table Four, below, shows the thickness of the titanium nitride layer before and after treatment with an ozonated acetic anhydride stripping solution containing 300 ppm (or mg/L) of ozone at room temperature (25° C.).
TABLE FOUR
Corrosivity of Ozonated Propionic
Acid Cleaning Solution on Copper
Change in
Pre-Treatment
Post-Treatment
Cu Layer
Treatment
Cu Thickness
Cu Thickness
Thickness
Sample #
Time (sec)
(Å)
(Å)
(Å)
12
30
18,266
18,293
+26
13
60
8,636
8,619
−17
14
120
9,777
9,726
−51
Within the accuracy of our ability to measure, the data in Table Four indicate that the thickness of the copper layer decreased only slightly upon exposure to ozonated acetic anhydride stripping solution.
While the invention has been described in detail above with reference to several embodiments, various modifications within the scope and spirit of the invention will be apparent to those of working skill in this technological field. Accordingly, the scope of the invention should be measured by the appended claims. | Described herein is a method of removing an organic-containing material from an exposed surface of a large substrate (at least 0.25 m 2 ). The substrate may comprise an electronic device. The exposed surface is treated with a stripping solution comprising ozone (O 3 ) in a solvent, where the solvent comprises acetic anhydride. The stripping solvent used to form the stripping solution may comprise a mixture of acetic anhydride with a co-solvent selected from the group consisting of a carbonate containing 2-4 carbon atoms, ethylene glycol diacetate, and combinations thereof. In some instances, the stripping solution may contain only acetic anhydride and ozone, where the ozone concentration is typically about 300 ppm or greater. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to thiazolium dyes, laundry care compositions comprising one or more thiazolium dyes, processes of making such dyes and laundry care compositions and methods of using same.
BACKGROUND OF THE INVENTION
[0002] Fabrics, typically lighter colored fabrics such as white fabrics, that are worn and/or laundered typically discolor. For example, white fabrics which are repeatedly laundered can exhibit a yellowing in color appearance which causes the fabric to look older and worn. In an effort to overcome such fabric discoloration, certain laundry detergent products include a hueing or bluing dye which attaches to fabric during the laundry wash and/or rinse cycle. Unfortunately, such hueing or bluing dye typically tends to accumulate on the fabric, thus giving the fabric an undesirable bluish tint. As a result, a chlorine treatment is generally employed to reduce the aforementioned accumulation of bluing dyes. While a chlorine treatment can be effective, it is an additional, inconvenient step in the laundry process. Additionally, a chlorine treatment is costly and harsh on fabrics—contributing to increased fabric degradation. Accordingly, a need exists for improved laundry care products which can counter the undesirable discoloration of fabrics, including the yellowing of white fabrics.
SUMMARY OF THE INVENTION
[0003] The present invention relates to thiazolium dyes, laundry care compositions comprising one or more thiazolium dyes, processes of making such dyes and laundry care compositions and methods of using same. The dyes, compositions and methods of the present invention are advantageous in providing improved hueing of fabric, including whitening of white fabric, while avoiding significant build up of bluing dyes on the fabric.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0004] As used herein, the term “laundry care composition” includes, unless otherwise indicated, granular, powder, liquid, gel, paste, bar form and/or flake type washing agents and/or fabric treatment compositions.
[0005] As used herein, the term “fabric treatment composition” includes, unless otherwise indicated, fabric softening compositions, fabric enhancing compositions, fabric freshening compositions and combinations there of. Such compositions may be, but need not be rinse added compositions.
[0006] As used herein, the articles including “the”, “a” and “an” when used in a claim, are understood to mean one or more of what is claimed or described.
[0007] As used herein, the terms “include”, “includes” and “including” are meant to be non-limiting.
[0008] As used herein, the term polyether is defined as at least two repeating ether units that are chemically bound via the ethers' oxygen atoms. Such polyethers may be derived from materials including but not limited to ethylene oxide, propylene oxide, butylene oxide, hexylene oxide, glycidol, epichlorohydrin, pentanerythritol, glucose or combinations thereof.
[0009] As used herein capped polyether means a polyether that terminates in an alkyl or aryl moiety, including but not limited to a moiety selected from methyl, ethyl, butyl, isopropyl, tertiary butyl, amyl, benzyl, pentyl, and acetyl moieties.
[0010] As used herein “EO” stands for an ethylene oxide moiety.
[0011] As used herein “PO” stands for a propylene oxide moiety.
[0012] The test methods disclosed in the Test Methods Section of the present application should be used to determine the respective values of the parameters of Applicants' inventions.
[0013] Unless otherwise noted, all component or composition levels are in reference to the active portion of that component or composition, and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources of such components or compositions.
[0014] All percentages and ratios are calculated by weight unless otherwise indicated. All percentages and ratios are calculated based on the total composition unless otherwise indicated.
[0015] It should be understood that every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
[0016] All documents cited are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.
Laundry Care Compositions
[0017] In one aspect, a laundry care composition that may comprise a laundry care ingredient and a suitable thiazolium dye is disclosed. Suitable thiazolium dyes include thiazolium dyes that exhibit good tinting efficiency during a laundry wash cycle without exhibiting excessive undesirable build up after laundering. Thus, undesirable bluing after repeated washings with the detergent compositions of the invention is avoided and costly and harsh chlorine treatments are unnecessary. Suitable thiazolium dyes include those thiazolium dyes that are described under the heading “Suitable Thiazolium Dyes” of the present specification.
[0018] In one aspect, the laundry care compositions disclosed in the present specification can employ the thiazolium dyes disclosed in the present specification as detailed by Formulae V through VIII of the present specification.
[0019] In one aspect suitable thiazolium dyes include thiazolium dye molecules numbers 1-80 as detailed in Tables 1 and 2 of the present specification.
[0020] In one aspect, suitable thiazolium dyes include thiazolium dye molecules numbers 1, 4, 5, 7, 8, 12, 13, 15, 16, 17, 21, 24, 25, 26, 30, 31, 33, 36, 38, 40, 45 and 48 as detailed in Tables 1 and 2 of the present specification.
[0021] In one aspect, suitable thiazolium dyes include thiazolium dye molecules numbers 12, 13, 15, 16, 24, 25, 26, 30, 31, 33, 36, 38, 40, 45 and 48 as detailed in Tables 1 and 2 of the present specification.
[0022] In one aspect, the laundry care compositions disclosed in the present specification can employ combinations of any of the suitable thiazolium dyes disclosed in the present specification.
[0023] In one aspect, the laundry care compositions disclosed in the present specification can employ a non-hueing dye in combination with the thiazolium dye. The non-hueing dye may be selected from non-hueing dyes disclosed in U.S. Patent Application 2005/028820 A1, U.S. Pat. No. 4,137,243, U.S. Pat. No. 4,601,725 and U.S. Pat. No. 4,871,371. While not being bound by theory, it is believed that the combination of both a thiazolium dye and a non-hueing dye allows for flexibility to color blend to a desired hue.
[0024] In one aspect, the laundry care compositions disclosed in the present specification can employ a non-hueing dye, that may be non-substantive in nature, in combination with the thiazolium dye. The combination of both a thiazolium dye and a non-hueing dye can allow customization of product color and fabric tint. In one aspect, Acid Blue 7 may be employed as a non-hueing, non-tinting dye.
[0025] In one aspect, any of the components, including the suitable thiazolium dyes, may be employed in the laundry care compositions in an encapsulated form. Such encapsulates may comprise one or more of such components.
[0026] In one aspect a laundry care compositions comprising a thiazolium dye and a laundry care ingredient and having a hueing efficiency of greater than 10 but less than 40, from about 15 to about 35, or even from about 15 to about 30 and a wash removability of from about 30% to about 85%, from about 40% to about 85%, from about 50% to about 85% are disclosed.
[0027] Suitable laundry care ingredients include, but are not limited to, those materials described in the present specification as useful aspects of the present invention, including adjunct materials as described in the present specification.
Liquid, Laundry Detergent Compositions
[0028] In one aspect, the laundry care compositions disclosed herein, may take the form of liquid, laundry detergent compositions. In one aspect, such compositions may be a heavy duty liquid composition. Such compositions may comprise a sufficient amount of a surfactant to provide the desired level of one or more cleaning properties, typically by weight of the total composition, from about 5% to about 90%, from about 5% to about 70% or even from about 5% to about 40% and a sufficient of suitable thiazolium dye that is described under the heading “Suitable Thiazolium Dyes” of the present specification, to provide a tinting effect to fabric washed in a solution containing the detergent, typically by weight of the total composition, from about 0.0001% to about 0.05%, or even from about 0.001% to about 0.01%.
[0029] The liquid detergent compositions comprise an aqueous, non-surface active liquid carrier. Generally, the amount of the aqueous, non-surface active liquid carrier employed in the compositions herein will be effective to solubilize, suspend or disperse the composition components. For example, the compositions may comprise, by weight, from about 5% to about 90%, from about 10% to about 70%, or even from about 20% to about 70% of an aqueous, non-surface active liquid carrier.
[0030] The most cost effective type of aqueous, non-surface active liquid carrier may be water. Accordingly, the aqueous, non-surface active liquid carrier component may be generally mostly, if not completely, water. While other types of water-miscible liquids, such alkanols, diols, other polyols, ethers, amines, and the like, have been conventionally been added to liquid detergent compositions as co-solvents or stabilizers, for purposes of the present invention, the utilization of such water-miscible liquids may be minimized to hold down composition cost. Accordingly, the aqueous liquid carrier component of the liquid detergent products herein will generally comprise water present in concentrations ranging from about 5% to about 90%, or even from about 20% to about 70%, by weight of the composition.
[0031] The liquid detergent compositions herein may take the form of an aqueous solution or uniform dispersion or suspension of surfactant, thiazolium dye, and certain optional other ingredients, some of which may normally be in solid form, that have been combined with the normally liquid components of the composition, such as the liquid alcohol ethoxylate nonionic, the aqueous liquid carrier, and any other normally liquid optional ingredients. Such a solution, dispersion or suspension will be acceptably phase stable and will typically have a viscosity which ranges from about 100 to 600 cps, more preferably from about 150 to 400 cps. For purposes of this invention, viscosity is measured with a Brookfield LVDV-II+ viscometer apparatus using a #21 spindle.
[0032] Suitable surfactants may be anionic, nonionic, cationic, zwitterionic and/or amphoteric surfactants. In one aspect, the detergent composition comprises anionic surfactant, nonionic surfactant, or mixtures thereof.
[0033] Suitable anionic surfactants may be any of the conventional anionic surfactant types typically used in liquid detergent products. Such surfactants include the alkyl benzene sulfonic acids and their salts as well as alkoxylated or non-alkoxylated alkyl sulfate materials.
[0034] Exemplary anionic surfactants are the alkali metal salts of C 10-16 alkyl benzene sulfonic acids, preferably C 11-14 alkyl benzene sulfonic acids. In one aspect, the alkyl group is linear. Such linear alkyl benzene sulfonates are known as “LAS”. Such surfactants and their preparation are described for example in U.S. Pat. Nos. 2,220,099 and 2,477,383. Especially preferred are the sodium and potassium linear straight chain alkylbenzene sulfonates in which the average number of carbon atoms in the alkyl group is from about 11 to 14. Sodium C 11 -C 14 , e.g., C 12 , LAS is a specific example of such surfactants.
[0035] Another exemplary type of anionic surfactant comprises ethoxylated alkyl sulfate surfactants. Such materials, also known as alkyl ether sulfates or alkyl polyethoxylate sulfates, are those which correspond to the formula: R′—O—(C 2 H 4 O) n —SO 3 M wherein R′ is a C 8 -C 20 alkyl group, n is from about 1 to 20, and M is a salt-forming cation. In a specific embodiment, R′ is C 10 -C 18 alkyl, n is from about 1 to 15, and M is sodium, potassium, ammonium, alkylammonium, or alkanolammonium. In more specific embodiments, R′ is a C 12 -C 16 , n is from about 1 to 6 and M is sodium.
[0036] The alkyl ether sulfates will generally be used in the form of mixtures comprising varying R′ chain lengths and varying degrees of ethoxylation. Frequently such mixtures will inevitably also contain some non-ethoxylated alkyl sulfate materials, i.e., surfactants of the above ethoxylated alkyl sulfate formula wherein n=0. Non-ethoxylated alkyl sulfates may also be added separately to the compositions of this invention and used as or in any anionic surfactant component which may be present. Specific examples of non-alkoyxylated, e.g., non-ethoxylated, alkyl ether sulfate surfactants are those produced by the sulfation of higher C 8 -C 20 fatty alcohols. Conventional primary alkyl sulfate surfactants have the general formula: ROSO 3 -M + wherein R is typically a linear C 8 -C 20 hydrocarbyl group, which may be straight chain or branched chain, and M is a water-solubilizing cation. In specific embodiments, R is a C 10 -C 15 alkyl, and M is alkali metal, more specifically R is C 12 -C 14 and M is sodium.
[0037] Specific, nonlimiting examples of anionic surfactants useful herein include: a) C 11 -C 18 alkyl benzene sulfonates (LAS); b) C 10 -C 20 primary, branched-chain and random alkyl sulfates (AS); c) C 10 -C 18 secondary (2,3) alkyl sulfates having formulae (I) and (II):
[0000]
[0000] wherein M in formulae (I) and (II) is hydrogen or a cation which provides charge neutrality, and all M units, whether associated with a surfactant or adjunct ingredient, can either be a hydrogen atom or a cation depending upon the form isolated by the artisan or the relative pH of the system wherein the compound is used, with non-limiting examples of preferred cations including sodium, potassium, ammonium, and mixtures thereof, and x is an integer of at least about 7, preferably at least about 9, and y is an integer of at least 8, preferably at least about 9; d) C 10 -C 18 alkyl alkoxy sulfates (AE X S) wherein preferably x is from 1-30; e) C 10 -C 18 alkyl alkoxy carboxylates preferably comprising 1-5 ethoxy units; f) mid-chain branched alkyl sulfates as discussed in U.S. Pat. No. 6,020,303 and U.S. Pat. No. 6,060,443; g) mid-chain branched alkyl alkoxy sulfates as discussed in U.S. Pat. No. 6,008,181 and U.S. Pat. No. 6,020,303; h) modified alkylbenzene sulfonate (MLAS) as discussed in WO 99/05243, WO 99/05242, WO 99/05244, WO 99/05082, WO 99/05084, WO 99/05241, WO 99/07656, WO 00/23549, and WO 00/23548; i) methyl ester sulfonate (MES); and j) alpha-olefin sulfonate (AOS).
[0038] Suitable nonionic surfactants useful herein can comprise any of the conventional nonionic surfactant types typically used in liquid detergent products. These include alkoxylated fatty alcohols and amine oxide surfactants. Preferred for use in the liquid detergent products herein are those nonionic surfactants which are normally liquid.
[0039] Suitable nonionic surfactants for use herein include the alcohol alkoxylate nonionic surfactants. Alcohol alkoxylates are materials which correspond to the general formula: R 1 (C m H 2m O) n OH wherein R 1 is a C 8 -C 16 alkyl group, m is from 2 to 4, and n ranges from about 2 to 12. Preferably R 1 is an alkyl group, which may be primary or secondary, that contains from about 9 to 15 carbon atoms, more preferably from about 10 to 14 carbon atoms. In one embodiment, the alkoxylated fatty alcohols will also be ethoxylated materials that contain from about 2 to 12 ethylene oxide moieties per molecule, more preferably from about 3 to 10 ethylene oxide moieties per molecule.
[0040] The alkoxylated fatty alcohol materials useful in the liquid detergent compositions herein will frequently have a hydrophilic-lipophilic balance (HLB) which ranges from about 3 to 17. More preferably, the HLB of this material will range from about 6 to 15, most preferably from about 8 to 15. Alkoxylated fatty alcohol nonionic surfactants have been marketed under the tradename Neodol® by the Shell Chemical Company.
[0041] Another suitable type of nonionic surfactant useful herein comprises the amine oxide surfactants. Amine oxides are materials which are often referred to in the art as “semi-polar” nonionics. Amine oxides have the formula: R(EO) x (PO) y (BO) n N(O)(CH 2 R′) 2 .qH 2 O. In this formula, R is a relatively long-chain hydrocarbyl moiety which can be saturated or unsaturated, linear or branched, and can contain from 8 to 20, preferably from 10 to 16 carbon atoms, and is more preferably C 12 -C 16 primary alkyl. R′ is a short-chain moiety, preferably selected from hydrogen, methyl and —CH 2 OH. When x+y+z is different from 0, EO is ethyleneoxy, PO is propyleneneoxy and BO is butyleneoxy. Amine oxide surfactants are illustrated by C 12-14 alkyldimethyl amine oxide.
[0042] Non-limiting examples of nonionic surfactants include: a) C 12 -C 18 alkyl ethoxylates, such as, NEODOL® nonionic surfactants from Shell; b) C 6 -C 12 alkyl phenol alkoxylates wherein the alkoxylate units are a mixture of ethyleneoxy and propyleneoxy units; c) C 12 -C 18 alcohol and C 6 -C 12 alkyl phenol condensates with ethylene oxide/propylene oxide block polymers such as Pluronic® from BASF; d) C 14 -C 22 mid-chain branched alcohols, BA, as discussed in U.S. Pat. No. 6,150,322; e) C 14 -C 22 mid-chain branched alkyl alkoxylates, BAE x , wherein x 1-30, as discussed in U.S. Pat. No. 6,153,577, U.S. Pat. No. 6,020,303 and U.S. Pat. No. 6,093,856; f) Alkylpolysaccharides as discussed in U.S. Pat. No. 4,565,647 Llenado, issued Jan. 26, 1986; specifically alkylpolyglycosides as discussed in U.S. Pat. No. 4,483,780 and U.S. Pat. No. 4,483,779; g) Polyhydroxy fatty acid amides as discussed in U.S. Pat. No. 5,332,528, WO 92/06162, WO 93/19146, WO 93/19038, and WO 94/09099; and h) ether capped poly(oxyalkylated) alcohol surfactants as discussed in U.S. Pat. No. 6,482,994 and WO 01/42408.
[0043] In the laundry detergent compositions herein, the detersive surfactant component may comprise combinations of anionic and nonionic surfactant materials. When this is the case, the weight ratio of anionic to nonionic will typically range from 10:90 to 90:10, more typically from 30:70 to 70:30.
[0044] Cationic surfactants are well known in the art and non-limiting examples of these include quaternary ammonium surfactants, which can have up to 26 carbon atoms. Additional examples include a) alkoxylate quaternary ammonium (AQA) surfactants as discussed in U.S. Pat. No. 6,136,769; b) dimethyl hydroxyethyl quaternary ammonium as discussed in U.S. Pat. No. 6,004,922; c) polyamine cationic surfactants as discussed in WO 98/35002, WO 98/35003, WO 98/35004, WO 98/35005, and WO 98/35006; d) cationic ester surfactants as discussed in U.S. Pat. Nos. 4,228,042, 4,239,660 4,260,529 and U.S. Pat. No. 6,022,844; and e) amino surfactants as discussed in U.S. Pat. No. 6,221,825 and WO 00/47708, specifically amido propyldimethyl amine (APA).
[0045] Non-limiting examples of zwitterionic surfactants include: derivatives of secondary and tertiary amines, derivatives of heterocyclic secondary and tertiary amines, or derivatives of quaternary ammonium, quaternary phosphonium or tertiary sulfonium compounds. See U.S. Pat. No. 3,929,678 to Laughlin et al., issued Dec. 30, 1975 at column 19, line 38 through column 22, line 48, for examples of zwitterionic surfactants; betaine, including alkyl dimethyl betaine and cocodimethyl amidopropyl betaine, C 8 to C 18 (preferably C 12 to C 18 ) amine oxides and sulfo and hydroxy betaines, such as N-alkyl-N,N-dimethylammino-1-propane sulfonate where the alkyl group can be C 8 to C 18 , preferably C 10 to C 14 .
[0046] Non-limiting examples of ampholytic surfactants include: aliphatic derivatives of secondary or tertiary amines, or aliphatic derivatives of heterocyclic secondary and tertiary amines in which the aliphatic radical can be straight- or branched-chain. One of the aliphatic substituents contains at least about 8 carbon atoms, typically from about 8 to about 18 carbon atoms, and at least one contains an anionic water-solubilizing group, e.g. carboxy, sulfonate, sulfate. See U.S. Pat. No. 3,929,678 to Laughlin et al., issued Dec. 30, 1975 at column 19, lines 18-35, for examples of ampholytic surfactants.
Granular Laundry Detergent Compositions
[0047] In one aspect, the laundry care compositions disclosed herein, may take the form of granular, laundry detergent compositions. Such compositions may comprise a sufficient of suitable thiazolium dye that is described under the heading “Suitable Thiazolium Dyes” of the present specification, to provide a tinting effect to fabric washed in a solution containing the detergent, typically by weight of the total composition, from about 0.0001% to about 0.05%, or even from about 0.001% to about 0.01%.
[0048] Granular detergent compositions of the present invention may include any number of conventional detergent ingredients. For example, the surfactant system of the detergent composition may include anionic, nonionic, zwitterionic, ampholytic and cationic classes and compatible mixtures thereof. Detergent surfactants for granular compositions are described in U.S. Pat. No. 3,664,961, Norris, issued May 23, 1972, and in U.S. Pat. No. 3,919,678, Laughlin et al., issued Dec. 30, 1975. Cationic surfactants include those described in U.S. Pat. No. 4,222,905, Cockrell, issued Sep. 16, 1980, and in U.S. Pat. No. 4,239,659, Murphy, issued Dec. 16, 1980.
[0049] Nonlimiting examples of surfactant systems include the conventional C 11 -C 18 alkyl benzene sulfonates (“LAS”) and primary, branched-chain and random C 10 -C 20 alkyl sulfates (“AS”), the C 10 -C 18 secondary (2,3) alkyl sulfates of the formula CH 3 (CH 2 ) x (CHOSO 3 − M + ) CH 3 and CH 3 (CH 2 ) y (CHOSO 3 − M + ) CH 2 CH 3 where x and (y+1) are integers of at least about 7, preferably at least about 9, and M is a water-solubilizing cation, especially sodium, unsaturated sulfates such as oleyl sulfate, the C 10 -C 18 alkyl alkoxy sulfates (“AE x S”; especially EO 1-7 ethoxy sulfates), C 10 -C 18 alkyl alkoxy carboxylates (especially the EO 1-5 ethoxycarboxylates), the C 10-18 glycerol ethers, the C 10 -C 18 alkyl polyglycosides and their corresponding sulfated polyglycosides, and C 12 -C 18 alpha-sulfonated fatty acid esters. If desired, the conventional nonionic and amphoteric surfactants such as the C 12 -C 18 alkyl ethoxylates (“AE”) including the so-called narrow peaked alkyl ethoxylates and C 6 -C 12 alkyl phenol alkoxylates (especially ethoxylates and mixed ethoxy/propoxy), C 12 -C 18 betaines and sulfobetaines (“sultaines”), C 10 -C 18 amine oxides, and the like, can also be included in the surfactant system. The C 10 -C 18 N-alkyl polyhydroxy fatty acid amides can also be used. See WO 9,206,154. Other sugar-derived surfactants include the N-alkoxy polyhydroxy fatty acid amides, such as C 10 -C 18 N-(3-methoxypropyl)glucamide. The N-propyl through N-hexyl C 12 -C 18 glucamides can be used for low sudsing. C 10 -C 20 conventional soaps may also be used. If high sudsing is desired, the branched-chain C 10 -C 16 soaps may be used. Mixtures of anionic and nonionic surfactants are especially useful. Other conventional useful surfactants are listed in standard texts.
[0050] The detergent composition can, and preferably does, include a detergent builder. Builders are generally selected from the various water-soluble, alkali metal, ammonium or substituted ammonium phosphates, polyphosphates, phosphonates, polyphosphonates, carbonates, silicates, borates, polyhydroxy sulfonates, polyacetates, carboxylates, and polycarboxylates. Preferred are the alkali metal, especially sodium, salts of the above. Preferred for use herein are the phosphates, carbonates, silicates, C 10-18 fatty acids, polycarboxylates, and mixtures thereof. More preferred are sodium tripolyphosphate, tetrasodium pyrophosphate, citrate, tartrate mono- and di-succinates, sodium silicate, and mixtures thereof.
[0051] Specific examples of inorganic phosphate builders are sodium and potassium tripolyphosphate, pyrophosphate, polymeric metaphosphate having a degree of polymerization of from about 6 to 21, and orthophosphates. Examples of polyphosphonate builders are the sodium and potassium salts of ethylene diphosphonic acid, the sodium and potassium salts of ethane 1-hydroxy-1,1-diphosphonic acid and the sodium and potassium salts of ethane, 1,1,2-triphosphonic acid. Other phosphorus builder compounds are disclosed in U.S. Pat. Nos. 3,159,581; 3,213,030; 3,422,021; 3,422,137; 3,400,176 and 3,400,148. Examples of nonphosphorus, inorganic builders are sodium and potassium carbonate, bicarbonate, sesquicarbonate, tetraborate decahydrate, and silicates having a weight ratio of SiO 2 to alkali metal oxide of from about 0.5 to about 4.0, preferably from about 1.0 to about 2.4. Water-soluble, nonphosphorus organic builders useful herein include the various alkali metal, ammonium and substituted ammonium polyacetates, carboxylates, polycarboxylates and polyhydroxy sulfonates. Examples of polyacetate and polycarboxylate builders are the sodium, potassium, lithium, ammonium and substituted ammonium salts of ethylene diamine tetraacetic acid, nitrilotriacetic acid, oxydisuccinic acid, mellitic acid, benzene polycarboxylic acids, and citric acid.
[0052] Polymeric polycarboxylate builders are set forth in U.S. Pat. No. 3,308,067, Diehl, issued Mar. 7, 1967. Such materials include the water-soluble salts of homo- and copolymers of aliphatic carboxylic acids such as maleic acid, itaconic acid, mesaconic acid, fumaric acid, aconitic acid, citraconic acid and methylenemalonic acid. Some of these materials are useful as the water-soluble anionic polymer as hereinafter described, but only if in intimate admixture with the nonsoap anionic surfactant. Other suitable polycarboxylates for use herein are the polyacetal carboxylates described in U.S. Pat. No. 4,144,226, issued Mar. 13, 1979 to Crutchfield et al., and U.S. Pat. No. 4,246,495, issued Mar. 27, 1979 to Crutchfield et al.
[0053] Water-soluble silicate solids represented by the formula SiO 2 .M 2 O, M being an alkali metal, and having a SiO 2 :M 2 O weight ratio of from about 0.5 to about 4.0, are useful salts in the detergent granules of the invention at levels of from about 2% to about 15% on an anhydrous weight basis. Anhydrous or hydrated particulate silicate can be utilized, as well.
[0054] Any number of additional ingredients can also be included as components in the granular detergent composition. These include other detergency builders, bleaches, bleach activators, suds boosters or suds suppressors, anti-tarnish and anti-corrosion agents, soil suspending agents, soil release agents, germicides, pH adjusting agents, nonbuilder alkalinity sources, chelating agents, smectite clays, enzymes, enzyme-stabilizing agents and perfumes. See U.S. Pat. No. 3,936,537, issued Feb. 3, 1976 to Baskerville, Jr. et al.
[0055] Bleaching agents and activators are described in U.S. Pat. No. 4,412,934, Chung et al., issued Nov. 1, 1983, and in U.S. Pat. No. 4,483,781, Hartman, issued Nov. 20, 1984. Chelating agents are also described in U.S. Pat. No. 4,663,071, Bush et al., from Column 17, line 54 through Column 18, line 68. Suds modifiers are also optional ingredients and are described in U.S. Pat. No. 3,933,672, issued Jan. 20, 1976 to Bartoletta et al., and U.S. Pat. No. 4,136,045, issued Jan. 23, 1979 to Gault et al. Suitable smectite clays for use herein are described in U.S. Pat. No. 4,762,645, Tucker et al., issued Aug. 9, 1988, Column 6, line 3 through Column 7, line 24. Suitable additional detergency builders for use herein are enumerated in the Baskerville patent, Column 13, line 54 through Column 16, line 16, and in U.S. Pat. No. 4,663,071, Bush et al., issued May 5, 1987.
Rinse Added Fabric Conditioning Compositions
[0056] In one aspect, the laundry care compositions disclosed herein, may take the form of rinse added fabric conditioning compositions. Such compositions may comprise a fabric softening active and a sufficient amount of suitable thiazolium dye, that is described under the heading “Suitable Thiazolium Dyes” of the present specification, to provide a tinting effect to fabric treated by the composition, typically from about 0.00001 wt. % (0.1 ppm) to about 1 wt. % (10,000 ppm), or even from about 0.0003 wt. % (3 ppm) to about 0.03 wt. % (300 ppm) based on total rinse added fabric conditioning composition weight. In another specific embodiment, the compositions are rinse added fabric conditioning compositions. Examples of typical rinse added conditioning composition can be found in U.S. Provisional Patent Application Ser. No. 60/687,582 filed on Oct. 8, 2004.
[0057] In one embodiment of the invention, the fabric softening active (hereinafter “FSA”) is a quaternary ammonium compound suitable for softening fabric in a rinse step. In one embodiment, the FSA is formed from a reaction product of a fatty acid and an aminoalcohol obtaining mixtures of mono-, di-, and, in one embodiment, triester compounds. In another embodiment, the FSA comprises one or more softener quaternary ammonium compounds such, but not limited to, as a monoalkyquaternary ammonium compound, a diamido quaternary compound and a diester quaternary ammonium compound, or a combination thereof.
[0058] In one aspect of the invention, the FSA comprises a diester quaternary ammonium (hereinafter “DQA”) compound composition. In certain embodiments of the present invention, the DQA compounds compositions also encompasses a description of diamido FSAs and FSAs with mixed amido and ester linkages as well as the aforementioned diester linkages, all herein referred to as DQA.
[0059] A first type of DQA (“DQA (1)”) suitable as a FSA in the present CFSC includes a compound comprising the formula:
[0000] {R 4-m —N + —[(CH 2 ) n —Y—R 1 ] m }X −
[0000] wherein each R substituent is either hydrogen, a short chain C 1 -C 6 , preferably C 1 -C 3 alkyl or hydroxyalkyl group, e.g., methyl (most preferred), ethyl, propyl, hydroxyethyl, and the like, poly (C 2 -C 3 alkoxy), preferably polyethoxy, group, benzyl, or mixtures thereof; each m is 2 or 3; each n is from 1 to about 4, preferably 2; each Y is —O—(O)C—, —C(O)—O—, —NR—C(O)—, or —C(O)—NR— and it is acceptable for each Y to be the same or different; the sum of carbons in each R 1 , plus one when Y is —O—(O)C— or —NR—C(O)—, is C 12 -C 22 , preferably C 14 -C 20 , with each R 1 being a hydrocarbyl, or substituted hydrocarbyl group; it is acceptable for R 1 to be unsaturated or saturated and branched or linear and preferably it is linear; it is acceptable for each R 1 to be the same or different and preferably these are the same; and X − can be any softener-compatible anion, preferably, chloride, bromide, methylsulfate, ethylsulfate, sulfate, phosphate, and nitrate, more preferably chloride or methyl sulfate. Preferred DQA compounds are typically made by reacting alkanolamines such as MDEA (methyldiethanolamine) and TEA (triethanolamine) with fatty acids. Some materials that typically result from such reactions include N,N-di(acyl-oxyethyl)-N,N-dimethylammonium chloride or N,N-di(acyl-oxyethyl)-N,N-methylhydroxyethylammonium methylsulfate wherein the acyl group is derived from animal fats, unsaturated, and polyunsaturated, fatty acids, e.g., tallow, hardened tallow, oleic acid, and/or partially hydrogenated fatty acids, derived from vegetable oils and/or partially hydrogenated vegetable oils, such as, canola oil, safflower oil, peanut oil, sunflower oil, corn oil, soybean oil, tall oil, rice bran oil, palm oil, etc. Non-limiting examples of suitable fatty acids are listed in U.S. Pat. No. 5,759,990 at column 4, lines 45-66. In one embodiment the FSA comprises other actives in addition to DQA (1) or DQA. In yet another embodiment, the FSA comprises only DQA (1) or DQA and is free or essentially free of any other quaternary ammonium compounds or other actives. In yet another embodiment, the FSA comprises the precursor amine that is used to produce the DQA.
[0060] In another aspect of the invention, the FSA comprises a compound, identified as DTTMAC comprising the formula:
[0000] [R 4-m —N (+) —R 1 m ]A −
[0000] wherein each m is 2 or 3, each R 1 is a C 6 -C 22 , preferably C 14 -C 20 , but no more than one being less than about C 12 and then the other is at least about 16, hydrocarbyl, or substituted hydrocarbyl substituent, preferably C 10 -C 20 alkyl or alkenyl (unsaturated alkyl, including polyunsaturated alkyl, also referred to sometimes as “alkylene”), most preferably C 12 -C 18 alkyl or alkenyl, and branch or unbranched. In one embodiment, the Iodine Value (IV) of the FSA is from about 1 to 70; each R is H or a short chain C 1 -C 6 , preferably C 1 -C 3 alkyl or hydroxyalkyl group, e.g., methyl (most preferred), ethyl, propyl, hydroxyethyl, and the like, benzyl, or (R 2 O) 2-4 H where each R 2 is a C 1 -C 6 alkylene group; and A − is a softener compatible anion, preferably, chloride, bromide, methylsulfate, ethylsulfate, sulfate, phosphate, or nitrate; more preferably chloride or methyl sulfate. Examples of these FSAs include dialkydimethylammonium salts and dialkylenedimethylammonium salts such as ditallowedimethylammonium and ditallowedimethylammonium methylsulfate. Examples of commercially available dialkylenedimethylammonium salts usable in the present invention are di-hydrogenated tallow dimethyl ammonium chloride and ditallowedimethyl ammonium chloride available from Degussa under the trade names Adogen® 442 and Adogen® 470 respectively. In one embodiment the FSA comprises other actives in addition to DTTMAC. In yet another embodiment, the FSA comprises only compounds of the DTTMAC and is free or essentially free of any other quaternary ammonium compounds or other actives.
[0061] In one embodiment, the FSA comprises an FSA described in U.S. Pat. Pub. No. 2004/0204337 A1, published Oct. 14, 2004 to Corona et al., from paragraphs 30-79.
[0062] In another embodiment, the FSA is one described in U.S. Pat. Pub. No. 2004/0229769 A1, published Nov. 18, 2005, to Smith et al., on paragraphs 26-31; or U.S. Pat. No. 6,494,920, at column 1, line 51 et seq. detailing an “esterquat” or a quaternized fatty acid triethanolamine ester salt.
[0063] In one embodiment, the FSA is chosen from at least one of the following: ditallowoyloxyethyl dimethyl ammonium chloride, dihydrogenated-tallowoyloxyethyl dimethyl ammonium chloride, ditallow dimethyl ammonium chloride, ditallowoyloxyethyl dimethyl ammonium methyl sulfate, dihydrogenated-tallowoyloxyethyl dimethyl ammonium chloride, dihydrogenated-tallowoyloxyethyl dimethyl ammonium chloride, or combinations thereof.
[0064] In one embodiment, the FSA may also include amide containing compound compositions. Examples of diamide comprising compounds may include but not limited to methyl-bis(tallowamidoethyl)-2-hydroxyethylammonium methyl sulfate (available from Degussa under the trade names Varisoft 110 and Varisoft 222). An example of an amide-ester containing compound is N-[3-(stearoylamino)propyl]-N-[2-(stearoyloxy)ethoxy)ethyl)]-N-methylamine.
[0065] Another specific embodiment of the invention provides for a rinse added fabric care composition further comprising a cationic starch. Cationic starches are disclosed in US 2004/0204337 A1. In one embodiment, the fabric care composition comprises from about 0.1% to about 7% of cationic starch by weight of the laundry care composition. In one embodiment, the cationic starch is HCP401 from National Starch.
Suitable Thiazolium Dyes
[0066] Suitable thiazolium dyes include azo dyes that may have Formula (I) below:
[0000]
[0067] wherein:
R 3 and R 4 may be identical or different and, independently of one another, are hydrogen, a saturated or unsaturated (C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkyl group substituted by a halogen atom, a hydroxy-(C 2 -C 22 )-alkyl group optionally interrupted by oxygen, a polyether group derived from ethylene oxide, propylene oxide or butylene oxide, an amino-(C 1 -C 22 )-alkyl group, a substituted or unsubstituted phenyl group or a benzyl group, a (C 1 -C 22 )-alkyl group terminated in sulfonate, sulfate, or carboxylate, or the radical groups R 3 and R 4 , together with the remaining molecule, can form a heterocyclic or carbocyclic, saturated or unsaturated, substituted or unsubstituted ring system optionally substituted by halogen, sulfate, sulfonate, phosphate, nitrate, and carboxylate; X may be a radical group of the phenol series or a heterocyclic radical group or aniline series or m-toluidine series that may have Formula II below;
[0000]
wherein:
R 5 and R 6 may be identical or different and, independently of one another, are a straight or branched saturated or unsaturated (C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkyl ether group, a hydroxy-(C 2 -C 22 )-alkyl group optionally interrupted by oxygen, a polyether group derived from ethylene oxide, propylene oxide, butylene oxide, glycidyl or combinations thereof, an amino-(C 1 -C 22 )-alkyl group, a substituted or unsubstituted phenyl group or a benzyl group, a linear or branched (C 1 -C 22 )-alkyl group terminated in a linear or branched (C 1 -C 22 )-alkyl, hydroxyl, acetate, sulfonate, sulfate, or carboxylate, group or R 5 and R 6 or R 5 and R 7 or R 6 and R 7 , together with the nitrogen atom, form a 5-membered to 6-membered ring system, which may comprise a further heteroatom; or R 5 and R 6 or R 5 and R 7 or R 6 and R 7 , form with a carbon atom of the benzene six-membered heterocycle which may be substituted with one or more (C 1 -C 22 )-alkyl group; R 7 may be identical or different and, independently of one another, are hydrogen, a halogen atom, a saturated or unsaturated (C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkyl ether group, a hydroxyl group, a hydroxy-(C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkoxy group, a cyano group, a nitro group, an amino group, a (C 1 -C 22 )-alkylamino group, a (C 1 -C 22 )-dialkylamino group, a carboxylic acid group, a C(O)O—(C 1 -C 22 )-alkyl group, a substituted or unsubstituted C(O)O-phenyl group;
Q − may be an anion that balances the overall charge of the compound of Formula I, and the index q may be either 0 or 1. Suitable anions include chloro, bromo, methosulfate, tetrafluoroborate, and acetate anions.
R 1 may be a (C 1 -C 22 )-alkyl, an alkyl aromatic or an alkyl sulfonate radical having Formula (III) below;
[0000]
wherein
R 2 is hydrogen, methyl, ethyl, propyl, acetate or a hydroxyl group; m and p are integers from 0 to (n−1), n is an integer from 1 to 6 and m+p=(n−1);
with the proviso that the heterocycle of the Formula (I) comprises at least two and at most three heteroatoms, where the heterocycle has at most one sulfur atom;
[0078] In one aspect, a suitable thiazolium dye may have Formula IV below:
[0000]
[0000] wherein R 8 and R 9 may be identical or different and, independently of one another, may be a saturated or unsaturated (C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkyl group, a hydroxy-(C 2 -C 22 )-alkyl group optionally interrupted by oxygen, a polyether group derived from ethylene oxide, propylene oxide or butylene oxide, an amino-(C 1 -C 22 )-alkyl group, a substituted or unsubstituted phenyl group or a benzyl group, a (C 1 -C 22 )-alkyl group terminated in sulfonate, sulfate, or carboxylate, or R 8 and R 9 , together with the nitrogen atom, may form a 5-membered to 6-membered ring system, which may comprise a further heteroatom; or R 8 or R 9 may form, with a carbon atom of the benzene ring, an optionally oxygen-containing or nitrogen containing five or six-membered heterocycle which may be substituted with one or more (C 1 -C 22 )-alkyl groups, and mixtures thereof, and R 10 is hydrogen or methyl. For Formula IV, Q − is as described for Formula I above.
[0079] In one aspect, suitable thiazolium dyes may have Formula (V);
[0000]
[0080] wherein:
a.) R 1 may be selected from a branched or unbranched (C 1 -C 22 )-alkyl moiety, an aromatic alkyl moiety, a polyalkylene oxide moiety or a moiety having Formula (VI) below;
[0000]
wherein
(i) R 2 may be selected from hydrogen, methyl, ethyl, propyl, acetate or a hydroxyl moiety; m and p may be, independently, integers from 0 to (n−1), with the proviso that n is an integer from 1 to 6 and m+p=(n−1) (ii) Y may be selected from a hydroxyl, sulfonate, sulfate, carboxylate or acetate moiety;
b.) R 3 and R 4 :
i.) may be independently selected from hydrogen; a saturated or unsaturated (C 1 -C 22 )-alkyl moiety; a hydroxy-(C 2 -C 22 )-alkyl moiety; a hydroxy-(C 2 -C 22 )-alkyl moiety comprising, in addition to the hydroxyl oxygen, an oxygen atom; a polyether moiety; an amino-(C 1 -C 22 )-alkyl moiety; a substituted or unsubstituted phenyl moiety; a substituted or unsubstituted benzyl moiety; a (C 1 -C 22 )-alkyl moiety terminated in sulfonate, sulfate, acetate, or carboxylate; or ii.) when taken together may form a saturated or unsaturated heterocyclic or carbocyclic moiety; or iii.) when taken together may form a saturated or unsaturated heterocyclic or carbocyclic moiety substituted by, sulfate, sulfonate, phosphate, nitrate, and carboxylate;
c.) X may be moiety having Formula VII below;
[0000]
wherein:
i.) R 5 and R 6 :
(a) may be independently selected from hydrogen; a saturated or unsaturated (C 1 -C 22 )-alkyl moiety; a hydroxy-(C 2 -C 22 )-alkyl moiety; a hydroxy-(C 2 -C 22 )-alkyl moiety comprising, in addition to the hydroxyloxygen, an oxygen atom; a capped or uncapped polyether moiety; an amino-(C 1 -C 22 )-alkyl moiety; a substituted or unsubstituted phenyl moiety; a substituted or unsubstituted benzyl moiety; a (C 1 -C 22 )-alkyl moiety comprising a terminating C 1 -C 4 alkyl ether, sulfonate, sulfate, acetate or carboxylate moiety; a thiazole moiety or (b) when taken together may form a saturated or unsaturated heterocyclic moiety; or (c) when taken together form a saturated or unsaturated heterocyclic moiety substituted by one or more, alkoxylate, sulfate, sulfonate, phosphate, nitrate, and/or carboxylate moieties; (d) when taken together with R 7 , R 8 , or R 7 and R 8 form one or more saturated or unsaturated heterocyclic moieties, optionally substituted by one or more alkoxylate, sulfate, sulfonate, phosphate, nitrate, and/or carboxylate moieties; or (e) when taken together form a thiazole moiety;
ii.) R 7 and R 8 may be independently selected from hydrogen or a saturated or unsaturated alkyl moiety;
d.) Q − may be an anion that balances the overall charge of the compound of Formula I, and the index q is 0 or 1. Suitable anions include chloro, bromo, methosulfate, tetrafluoroborate, and acetate anions.
[0099] In one aspect, for Formula V:
[0100] a.) R 1 may be a methyl moiety;
[0101] b.) R 3 and R 4 may be hydrogen; and
[0102] c.) X may have Formula VIII below:
[0000]
wherein
(i) R 5 and R 6 may be as defined for Formula VII above; (ii) R 7 may be hydrogen or a methyl moiety; and (iii) R 8 may be hydrogen.
[0107] In one aspect, for Formula VII R 5 and R 6 each comprise, independently, from 1 to 20 alkylene oxide units and, independently, a moiety selected from the group consisting of: styrene oxide, glycidyl methyl ether, isobutyl glycidyl ether, isopropylglycidyl ether, t-butyl glycidyl ether, 2-ethylhexylgycidyl ether, or glycidylhexadecyl ether.
[0108] In one aspect, suitable thiazolium dyes are set forth in Table 1 below and are defined as Table 1 Thiazolium Dyes. The chemical names, as determined by ChemFinder software Level:Pro; Version 9.0 available from CambridgeSoft, Cambridge, Mass., U.S.A., for such dyes are respectively provided in Table 2 below. Such dyes are associated, as needed to balance the molecule's charge, with an anion Q − . Such anion is not shown in the structures below but for the purposes of the present specification is assumed to be present as required. Such anion is as described above for Formula (I).
[0000]
TABLE 1
No.
Structure
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
[0000]
TABLE 2
No.
Name
1
(E)-2-((4-(benzyl(methyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
2
(E)-2-((4-(dimethylamino)phenyl)diazenyl)-3-methylthiazol-3-ium
3
(E)-2-((4-(bis(2-hydroxyethyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
4
(E)-2-((4-(bis(2-(2-(2-hydroxyethoxy)ethoxy)ethyl)amino)phenyl)diazenyl)-
3-methylthiazol-3-ium
5
(E)-2-((4-(bis(2-(2-hydroxyethoxy)ethyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
6
(E)-2-((4-(bis(14-hydroxy-5,8,11-trimethyl-3,6,9,12-
tetraoxapentadecyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
7
(E)-2-((4-(bis(2-(2-(2-(2-
hydroxypropoxy)propoxy)propoxy)ethyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
8
(E)-2-((4-(bis(2-(2-(2-
hydroxypropoxy)propoxy)ethyl)amino)phenyl)diazenyl)-3-methylthiazol-3-
ium
9
(E)-2-((4-(bis(35-hydroxy-5,8,11,14,17,20,23-heptamethyl-
3,6,9,12,15,18,21,24,27,30,33-undecaoxapentatriacontyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
10
(E)-2-((4-(bis(3-(2,3-dihydroxypropoxy)-2-hydroxypropyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
11
(E)-2-((4-(bis(2,3-dihydroxypropyl)amino)-2-methylphenyl)diazenyl)-3-
methylthiazol-3-ium
12
(E)-2-((4-((2-hydroxy-3-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)propyl)(2-
hydroxy-3-(2-(2-hydroxyethoxy)ethoxy)propyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
13
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium
14
(E)-2-((4-(bis(35-hydroxy-17,20,23,26,29,32-hexamethyl-
3,6,9,12,15,18,21,24,27,30,33-undecaoxahexatriacontyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
15
(E)-2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
16
(E)-2-((4-((2-(2-(2-acetoxyethoxy)ethoxy)ethyl)(2-(2-
acetoxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium
17
(E)-2-((4-(benzyl(2,3-dihydroxypropyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
18
(E)-2-(2-((4-(bis(35-hydroxy-17,20,23,26,29,32-hexamethyl-
3,6,9,12,15,18,21,24,27,30,33-undecaoxahexatriacontyl)amino)-2-
methylphenyl)diazenyl)thiazol-3-ium-3-yl)acetate
19
(E)-2-((4-(benzyl(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
20
(E)-2-((4-((2-tert-butoxy-15-hydroxy-6,9,12-trimethyl-4,7,10,13-
tetraoxahexadecyl)(2-(tert-butoxymethyl)-17-hydroxy-5,8,11,14-tetramethyl-
3,6,9,12,15-pentaoxaoctadecyl)amino)phenyl)diazenyl)-3-methylthiazol-3-
ium
21
(E)-2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
22
(E)-2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-5-methoxy-3-methylbenzo[d]thiazol-3-ium
23
(E)-2-(2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium-3-
yl)acetate
24
(E)-2-((4-(ethyl(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
25
(E)-2-((4-(benzyl(1,17-dihydroxy-3,6,9,12,15-pentaoxaoctadecan-18-
yl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
26
(E)-2-((4-((2-(2-(2-(2,3-dihydroxypropoxy)ethoxy)ethoxy)ethyl)(2-(2-(2,3-
dihydroxypropoxy)ethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-
methylthiazol-3-ium
27
(E)-2-(2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-6-methoxybenzo[d]thiazol-3-ium-3-yl)acetate
28
(E)-2-((4-((3-tert-butoxy-2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)propyl)(3-
tert-butoxy-2-(2-(2-hydroxyethoxy)ethoxy)propyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
29
(E)-2-((4-((3-butoxy-2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)propyl)(3-
butoxy-2-(2-(2-hydroxyethoxy)ethoxy)propyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
30
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)-3-isopropoxypropyl)(2-(2-(2-(2-
hydroxyethoxy)ethoxy)ethoxy)-3-isopropoxypropyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
31
(E)-2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
32
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)-3-(tridecyloxy)propyl)(2-(2-(2-(2-
hydroxyethoxy)ethoxy)ethoxy)-3-(tridecyloxy)propyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
33
(E)-3-ethyl-2-((4-(ethyl(23-hydroxy-3,6,9,12,15,18,21-
heptaoxatricosyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium
34
(E)-2-((4-(bis(2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)ethyl)amino)-2-
methylphenyl)diazenyl)-3-ethylthiazol-3-ium
35
(E)-2-((1-(29-hydroxy-3,6,9,12,15,18,21,24,27-nonaoxanonacosyl)-1,2,3,4-
tetrahydroquinolin-6-yl)diazenyl)-3-methylthiazol-3-ium
36
(E)-2-((4-((2-(2-hydroxypropoxy)ethyl)(2-(2-(2-
hydroxypropoxy)propoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-
methylthiazol-3-ium
37
(E)-2-((4-(bis(2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)ethyl)amino)-2-
methylphenyl)diazenyl)-3-ethylthiazol-3-ium
38
(E)-2-((4-(ethyl(23-hydroxy-3,6,9,12,15,18,21-heptaoxatricosyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
39
(E)-2-((4-(benzyl(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-3-ethylthiazol-3-ium
40
(E)-3-ethyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium
41
(E)-3-(2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium-3-
yl)propane-1-sulfonate
42
(E)-4-(2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium-3-
yl)butane-1-sulfonate
43
(E)-2-((4-(bis(2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)ethyl)amino)-2-
methylphenyl)diazenyl)-3-ethylthiazol-3-ium
44
(E)-3-benzyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)phenyl)diazenyl)thiazol-3-ium
45
(E)-3-ethyl-2-((4-((2-(2-hydroxypropoxy)ethyl)(2-(2-(2-
hydroxypropoxy)propoxy)ethyl)amino)-2-methylphenyl)diazenyl)thiazol-3-
ium
46
(E)-3-benzyl-2-((1-(29-hydroxy-3,6,9,12,15,18,21,24,27-nonaoxanonacosyl)-
1,2,3,4-tetrahydroquinolin-6-yl)diazenyl)thiazol-3-ium
47
(E)-3-benzyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium
48
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)propyl)(2-(2-
hydroxyethoxy)propyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium
49
(E)-2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
50
(E)-2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2,6-
dimethylphenyl)diazenyl)-3-methylthiazol-3-ium
51
(E)-2-((4-((4-(17-hydroxy-3,6,9,12,15-pentaoxaheptadecyloxy)-3-
methoxybenzyl)(methyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium
52
(E)-2-((1-(1-hydroxy-2,5,8,11,14,17,20,23,26-nonaoxaoctacosan-28-yl)-
1,2,3,4-tetrahydroquinolin-6-yl)diazenyl)-3-methylthiazol-3-ium
53
(E)-4-(2-((4-(dimethylamino)phenyl)diazenyl)thiazol-3-ium-3-yl)butane-1-
sulfonate
54
(E)-4-(2-((4-(dimethylamino)phenyl)diazenyl)-5-methylthiazol-3-ium-3-
yl)butane-1-sulfonate
55
(E)-2-((4-((2-hydroxyethyl)(methyl)amino)phenyl)diazenyl)-3-methylthiazol-
3-ium
56
(E)-2-(methyl(4-((3-methylthiazol-3-ium-2-yl)diazenyl)phenyl)amino)ethyl
sulfate
57
(E)-2-((4-(butyl(2-(2-hydroxyethoxy)ethyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
58
(E)-2-((4-(bis(2-(2-(2-
hydroxypropoxy)propoxy)ethyl)amino)phenyl)diazenyl)-3-methylthiazol-3-
ium
59
(E)-2-((4-((2-hydroxyethyl)(isopropyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
60
(E)-2-((4-((14-hydroxy-3,6,9,12-tetraoxatetradecyl)(1-hydroxy-3,6,9,13-
tetraoxapentadecan-15-yl)amino)-2-methylphenyl)diazenyl)-6-methoxy-3-
methylbenzo[d]thiazol-3-ium
61
(E)-2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
62
(E)-2-((4-(benzyl(3-(3-(3-(2,3-dihydroxypropoxy)-2-hydroxypropoxy)-2-
hydroxypropoxy)-2-hydroxypropyl)amino)-2-methylphenyl)diazenyl)-3-
methylthiazol-3-ium
63
(E)-3-(2-((4-(bis(2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)ethyl)amino)-2-
methylphenyl)diazenyl)thiazol-3-ium-3-yl)propane-1-sulfonate
64
(E)-2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2,5-
dimethylphenyl)diazenyl)-6-methoxy-3-methylbenzo[d]thiazol-3-ium
65
(E)-3-ethyl-2-((4-(ethyl(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)thiazol-3-ium
66
(E)-3-ethyl-2-((1-(29-hydroxy-3,6,9,12,15,18,21,24,27-nonaoxanonacosyl)-
1,2,3,4-tetrahydroquinolin-6-yl)diazenyl)thiazol-3-ium
67
(E)-3-ethyl-2-((1-(29-hydroxy-3,6,9,12,15,18,21,24,27-nonaoxanonacosyl)-
1,2,3,4-tetrahydroquinolin-6-yl)diazenyl)thiazol-3-ium
68
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3,5-dimethylthiazol-
3-ium
69
(E)-3-ethyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-5-methylthiazol-3-
ium
70
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3,5-dimethylthiazol-
3-ium
71
(E)-3-ethyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-5-methylthiazol-3-
ium
72
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3,5-dimethylthiazol-
3-ium
73
2-((E)-(4-((14-hydroxy-3,6,9,12-tetraoxatetradecyl)(17-hydroxy-3-(4-((E)-
thiazol-2-yldiazenyl)phenyl)-6,9,12,15-tetraoxa-3-
azaheptadecyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
74
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methyl-5-
nitrothiazol-3-ium
75
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methyl-5-
nitrothiazol-3-ium
76
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium-4-carboxylate
77
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3,5-dimethylthiazol-
3-ium-4-carboxylate
78
(E)-2-((4-(benzyl(2-(tert-butoxymethyl)-17-hydroxy-3,6,9,12,15-
pentaoxaheptadecyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
79
(E)-2-((4-((2-(tert-butoxymethyl)-14-hydroxy-3,6,9,12-
tetraoxatetradecyl)(ethyl)amino)-2-hydroxyphenyl)diazenyl)-3-methylthiazol-
3-ium
80
(E)-2-((4-((13-(sec-butoxymethyl)-1-hydroxy-3,6,9,12-tetraoxapentadecan-
15-yl)(2-(sec-butoxymethyl)-14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-
2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
[0109] In one aspect, suitable thiazolium dyes include thiazolium dye molecules numbers 1, 4, 5, 7, 8, 12, 13, 15, 16, 17, 21, 24, 25, 26, 30, 31, 33, 36, 38, 40, 45 and 48 as detailed in Tables 1 and 2 of the present specification.
[0110] In one aspect, suitable thiazolium dyes include thiazolium dye molecules numbers 12, 13, 15, 16, 24, 25, 26, 30, 31, 33, 36, 38, 40, 45 and 48 as detailed in Tables 1 and 2 of the present specification.
[0111] The suitable thiazolium dyes disclosed herein may be made by procedures known in the art and/or in accordance with the examples of the present specification.
Adjunct Materials
[0112] While not essential for the purposes of the present invention, the non-limiting list of adjuncts illustrated hereinafter are suitable for use in the laundry care compositions and may be desirably incorporated in certain embodiments of the invention, for example to assist or enhance performance, for treatment of the substrate to be cleaned, or to modify the aesthetics of the composition as is the case with perfumes, colorants, dyes or the like. It is understood that such adjuncts are in addition to the components that were previously listed for any particular embodiment. The total amount of such adjuncts may range from about 0.1% to about 50%, or even from about 1% to about 30%, by weight of the laundry care composition.
[0113] The precise nature of these additional components, and levels of incorporation thereof, will depend on the physical form of the composition and the nature of the operation for which it is to be used. Suitable adjunct materials include, but are not limited to, polymers, for example cationic polymers, surfactants, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic materials, bleach activators, polymeric dispersing agents, clay soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, additional perfume and perfume delivery systems, structure elasticizing agents, fabric softeners, carriers, hydrotropes, processing aids and/or pigments. In addition to the disclosure below, suitable examples of such other adjuncts and levels of use are found in U.S. Pat. Nos. 5,576,282, 6,306,812 B1 and 6,326,348 B1 that are incorporated by reference.
[0114] As stated, the adjunct ingredients are not essential to Applicants' cleaning and laundry care compositions. Thus, certain embodiments of Applicants' compositions do not contain one or more of the following adjuncts materials: bleach activators, surfactants, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic metal complexes, polymeric dispersing agents, clay and soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, additional perfumes and perfume delivery systems, structure elasticizing agents, fabric softeners, carriers, hydrotropes, processing aids and/or pigments. However, when one or more adjuncts are present, such one or more adjuncts may be present as detailed below:
[0115] Surfactants—The compositions according to the present invention can comprise a surfactant or surfactant system wherein the surfactant can be selected from nonionic and/or anionic and/or cationic surfactants and/or ampholytic and/or zwitterionic and/or semi-polar nonionic surfactants. The surfactant is typically present at a level of from about 0.1%, from about 1%, or even from about 5% by weight of the cleaning compositions to about 99.9%, to about 80%, to about 35%, or even to about 30% by weight of the cleaning compositions.
[0116] Builders—The compositions of the present invention can comprise one or more detergent builders or builder systems. When present, the compositions will typically comprise at least about 1% builder, or from about 5% or 10% to about 80%, 50%, or even 30% by weight, of said builder. Builders include, but are not limited to, the alkali metal, ammonium and alkanolammonium salts of polyphosphates, alkali metal silicates, alkaline earth and alkali metal carbonates, aluminosilicate builders polycarboxylate compounds. ether hydroxypolycarboxylates, copolymers of maleic anhydride with ethylene or vinyl methyl ether, 1,3,5-trihydroxybenzene-2,4,6-trisulphonic acid, and carboxymethyl-oxysuccinic acid, the various alkali metal, ammonium and substituted ammonium salts of polyacetic acids such as ethylenediamine tetraacetic acid and nitrilotriacetic acid, as well as polycarboxylates such as mellitic acid, succinic acid, oxydisuccinic acid, polymaleic acid, benzene 1,3,5-tricarboxylic acid, carboxymethyloxysuccinic acid, and soluble salts thereof.
[0117] Chelating Agents—The compositions herein may also optionally contain one or more copper, iron and/or manganese chelating agents. If utilized, chelating agents will generally comprise from about 0.1% by weight of the compositions herein to about 15%, or even from about 3.0% to about 15% by weight of the compositions herein.
[0118] Dye Transfer Inhibiting Agents—The compositions of the present invention may also include one or more dye transfer inhibiting agents. Suitable polymeric dye transfer inhibiting agents include, but are not limited to, polyvinylpyrrolidone polymers, polyamine N-oxide polymers, copolymers of N-vinylpyrrolidone and N-vinylimidazole, polyvinyloxazolidones and polyvinylimidazoles or mixtures thereof. When present in the compositions herein, the dye transfer inhibiting agents are present at levels from about 0.0001%, from about 0.01%, from about 0.05% by weight of the cleaning compositions to about 10%, about 2%, or even about 1% by weight of the cleaning compositions.
[0119] Dispersants—The compositions of the present invention can also contain dispersants. Suitable water-soluble organic materials are the homo- or co-polymeric acids or their salts, in which the polycarboxylic acid may comprise at least two carboxyl radicals separated from each other by not more than two carbon atoms.
[0120] Enzymes—The compositions can comprise one or more detergent enzymes which provide cleaning performance and/or fabric care benefits. Examples of suitable enzymes include, but are not limited to, hemicellulases, peroxidases, proteases, cellulases, xylanases, lipases, phospholipases, esterases, cutinases, pectinases, keratanases, reductases, oxidases, phenoloxidases, lipoxygenases, ligninases, pullulanases, tannases, pentosanases, malanases, β-glucanases, arabinosidases, hyaluronidase, chondroitinase, laccase, and amylases, or mixtures thereof. A typical combination is a cocktail of conventional applicable enzymes like protease, lipase, cutinase and/or cellulase in conjunction with amylase.
[0121] Enzyme Stabilizers—Enzymes for use in compositions, for example, detergents can be stabilized by various techniques. The enzymes employed herein can be stabilized by the presence of water-soluble sources of calcium and/or magnesium ions in the finished compositions that provide such ions to the enzymes.
[0122] Catalytic Metal Complexes—Applicants' compositions may include catalytic metal complexes. One type of metal-containing bleach catalyst is a catalyst system comprising a transition metal cation of defined bleach catalytic activity, such as copper, iron, titanium, ruthenium, tungsten, molybdenum, or manganese cations, an auxiliary metal cation having little or no bleach catalytic activity, such as zinc or aluminum cations, and a sequestrate having defined stability constants for the catalytic and auxiliary metal cations, particularly ethylenediaminetetraacetic acid, ethylenediaminetetra (methyl-enephosphonic acid) and water-soluble salts thereof. Such catalysts are disclosed in U.S. Pat. No. 4,430,243.
[0123] If desired, the compositions herein can be catalyzed by means of a manganese compound. Such compounds and levels of use are well known in the art and include, for example, the manganese-based catalysts disclosed in U.S. Pat. No. 5,576,282.
[0124] Cobalt bleach catalysts useful herein are known, and are described, for example, in U.S. Pat. Nos. 5,597,936 and 5,595,967. Such cobalt catalysts are readily prepared by known procedures, such as taught for example in U.S. Pat. Nos. 5,597,936, and 5,595,967.
[0125] Compositions herein may also suitably include a transition metal complex of a macropolycyclic rigid ligand—abbreviated as “MRL”. As a practical matter, and not by way of limitation, the compositions and cleaning processes herein can be adjusted to provide on the order of at least one part per hundred million of the benefit agent MRL species in the aqueous washing medium, and may provide from about 0.005 ppm to about 25 ppm, from about 0.05 ppm to about 10 ppm, or even from about 0.1 ppm to about 5 ppm, of the MRL in the wash liquor.
[0126] Preferred transition-metals in the instant transition-metal bleach catalyst include manganese, iron and chromium. Preferred MRL's herein are a special type of ultra-rigid ligand that is cross-bridged such as 5,12-diethyl-1,5,8,12-tetraazabicyclo[6.6.2]hexa-decane.
[0127] Suitable transition metal MRLs are readily prepared by known procedures, such as taught for example in WO 00/32601, and U.S. Pat. No. 6,225,464.
Processes of Making Laundry Care Compositions
[0128] The laundry care compositions of the present invention can be formulated into any suitable form and prepared by any process chosen by the formulator, non-limiting examples of which are described in U.S. Pat. No. 5,879,584; U.S. Pat. No. 5,691,297; U.S. Pat. No. 5,574,005; U.S. Pat. No. 5,569,645; U.S. Pat. No. 5,565,422; U.S. Pat. No. 5,516,448; U.S. Pat. No. 5,489,392; and U.S. Pat. No. 5,486,303.
[0129] In one aspect, the liquid detergent compositions disclosed herein may be prepared by combining the components thereof in any convenient order and by mixing, e.g., agitating, the resulting component combination to form a phase stable liquid detergent composition. In one aspect, a liquid matrix is formed containing at least a major proportion, or even substantially all, of the liquid components, e.g., nonionic surfactant, the non-surface active liquid carriers and other optional liquid components, with the liquid components being thoroughly admixed by imparting shear agitation to this liquid combination. For example, rapid stirring with a mechanical stirrer may usefully be employed. While shear agitation is maintained, substantially all of any anionic surfactant and the solid ingredients can be added. Agitation of the mixture is continued, and if necessary, can be increased at this point to form a solution or a uniform dispersion of insoluble solid phase particulates within the liquid phase. After some or all of the solid-form materials have been added to this agitated mixture, particles of any enzyme material to be included, e.g., enzyme prills, are incorporated. As a variation of the composition preparation procedure described above, one or more of the solid components may be added to the agitated mixture as a solution or slurry of particles premixed with a minor portion of one or more of the liquid components. After addition of all of the composition components, agitation of the mixture is continued for a period of time sufficient to form compositions having the requisite viscosity and phase stability characteristics. Frequently this will involve agitation for a period of from about 30 to 60 minutes.
[0130] In another aspect of producing liquid detergents, the thiazolium dye is first combined with one or more liquid components to form a thiazolium dye premix, and this thiazolium dye premix is added to a composition formulation containing a substantial portion, for example more than 50% by weight, more than 70% by weight, or even more than 90% by weight, of the balance of components of the laundry detergent composition. For example, in the methodology described above, both the thiazolium dye premix and the enzyme component are added at a final stage of component additions. In another aspect, the thiazolium dye is encapsulated prior to addition to the detergent composition, the encapsulated dye is suspended in a structured liquid, and the suspension is added to a composition formulation containing a substantial portion of the balance of components of the laundry detergent composition.
[0131] Various techniques for forming detergent compositions in such solid forms are well known in the art and may be used herein. In one aspect, when the laundry care composition is in the form of a granular particle, the thiazolium dye is provided in particulate form, optionally including additional but not all components of the laundry detergent composition. The thiazolium dye particulate is combined with one or more additional particulates containing a balance of components of the laundry detergent composition. Further, the thiazolium dye, optionally including additional but not all components of the laundry detergent composition may be provided in an encapsulated form, and the thiazolium dye encapsulate is combined with particulates containing a substantial balance of components of the laundry detergent composition.
Methods of Using Laundry Care Compositions
[0132] The laundry care compositions disclosed in the present specification may be used to clean or treat a fabric. Typically at least a portion of the fabric is contacted with an embodiment of the aforementioned laundry care compositions, in neat form or diluted in a liquor, for example, a wash liquor and then the fabric may be optionally washed and/or rinsed. In one aspect, a fabric is optionally washed and/or rinsed, contacted with a an embodiment of the aforementioned laundry care compositions and then optionally washed and/or rinsed. For purposes of the present invention, washing includes but is not limited to, scrubbing, and mechanical agitation. The fabric may comprise most any fabric capable of being laundered or treated.
[0133] The laundry care compositions disclosed in the present specification can be used to form aqueous washing solutions for use in the laundering of fabrics. Generally, an effective amount of such compositions is added to water, preferably in a conventional fabric laundering automatic washing machine, to form such aqueous laundering solutions. The aqueous washing solution so formed is then contacted, preferably under agitation, with the fabrics to be laundered therewith. An effective amount of the laundry care composition, such as the liquid detergent compositions disclosed in the present specification, may be added to water to form aqueous laundering solutions that may comprise from about 500 to about 7,000 ppm or even from about 1,000 to about 3,000 pm of laundry care composition.
[0134] In one aspect, one or more of the thiazolium dyes disclosed in the present specification may be provided, for example via a laundry care composition, such that during the wash cycle and or rinse cycle the concentration of such one or more dyes may be from about 0.5 parts per billion (ppb) to about 5 part per million (ppm), from about 1 ppb to about 600 ppb, from about 5 ppb to about 300 ppb, or even from about 10 ppb to about 100 ppb of thiazolium dye. In one aspect such concentrations may be achieved during the washing cycle, and/or rinse cycle, of a 17 gallon automatic laundry washing machine.
[0135] In one aspect, the laundry care compositions may be employed as a laundry additive, a pre-treatment composition and/or a post-treatment composition.
Test Methods
I. Method for Determining of Hueing Efficiency for Detergents
[0000]
a.) Two 25 cm×25 cm fabric swatches of 16 oz white cotton interlock knit fabric (270 g/square meter, brightened with Uvitex BNB fluorescent whitening agent, from Test Fabrics. P.O. Box 26, Weston, Pa., 18643), are obtained.
b.) Prepare two one liter aliquots of tap water containing 1.55 g of AATCC standard heavy duty liquid (HDL) test detergent as set forth in Table 3.
c.) Add a sufficient amount the dye to be tested to one of the aliquots from Step b.) above to produce an aqueous solution absorbance of 1 AU.
d.) Wash one swatch from a.) above in one of the aliquots of water containing 1.55 g of AATCC standard heavy duty liquid (HDL) test detergent and wash the other swatch in the other aliquot. Such washing step should be conducted for 30 minutes at room temperature with agitation. After such washing step separately rinse the swatches and dry the swatches.
e.) After rinsing and drying each swatch, the hueing efficiency, DE* eff , of the dye is assessed by determining the L*, a*, and b* value measurements of each swatch using a Hunter LabScan XE reflectance spectrophotometer with D65 illumination, 10° observer and UV filter excluded. The hueing efficiency of the dye is then calculated using the following equation:
[0000] DE* eff =(( L* c −L* s ) 2 +( a* c −a* s )+( b* c −b* s ) 2 ) 1/2 , wherein the subscripts c and s respectively refer to the L*, a*, and b* values measured for the control, i.e., the fabric sample washed in detergent with no dye, and the fabric sample washed in detergent containing the dye to be screened.
II. Method for Determining Wash Removability
[0000]
a.) Prepare two separate 150 ml aliquots of HDL detergent solution set forth in Table 1, according to AATCC Test Method 61-2003, Test 2A and containing 1.55 g/liter of the AATCC HDL formula in distilled water.
b.) A 15 cm×5 cm sample of each fabric swatch from the Method for Determining of Hueing Efficiency For Detergents described above is washed in a Launderometer for 45 minutes at 49° C. in 150 ml of a the HDL detergent solution prepared according to Step II. a.) above.
c.) The samples are rinsed with separate aliquots of rinse water and air dried in the dark, the amount of residual coloration is assessed by measuring the DE* res , of the dye is assessed by determining the L*, a*, and b* value measurements of each swatch using a Hunter LabScan XE reflectance spectrophotometer with D65 illumination, 10° observer and UV filter excluded. The hueing efficiency of the dye is then calculated using the following equation:
[0000] DE* res =(( L* c −L* s ) 2 +( a* c −a* s ) 2 ( b* c −b* s ) 2 ) 1/2 wherein the subscripts c and s respectively refer to the L*, a*, and b* values measured for the control, i.e., the fabric sample initially washed in detergent with no dye, and the fabric sample initially washed in detergent containing the dye to be screened. The wash removal value for the dye is then calculated according to the formula:
[0000] % removal=100×(1 −DE* res /DE* eff ).
[0000]
TABLE 3
Ingredient
weight percent
C11.8 linear alkylbenzene sulfonic acid
12.00
Neodol 23-9
8.00
citric acid
1.20
C12-14 fatty acid
4.00
sodium hydroxide 1
2.65
ethanolamine
0.13
borax
1.00
DTPA 2
0.30
1,2-propanediol
8.00
brightener 15
0.04
water
balance
1 formula pH adjusted to 8.5
2 diethylenetriaminepentaacetic acid, pentasodium salt
EXAMPLES
[0146] The following examples illustrate the compositions of the present invention but are not necessarily meant to limit or otherwise define the scope of the invention herein.
Example 1
[0147] The following liquid formulas are within the scope of the present invention.
[0000]
1a
1b
1c
1d
1e
1f 5
Ingredient
wt %
wt %
wt %
wt %
wt %
wt %
sodium alkyl ether sulfate
14.4%
14.4%
9.2%
5.4%
linear alkylbenzene
4.4%
4.4%
12.2%
5.7%
1.3%
22.0%
sulfonic acid
alkyl ethoxylate
2.2%
2.2%
8.8%
8.1%
3.4%
18.0%
amine oxide
0.7%
0.7%
1.5%
citric acid
2.0%
2.0%
3.4%
1.9%
1.0%
1.6%
fatty acid
3.0%
3.0%
8.3%
16.0%
protease
1.0%
1.0%
0.7%
1.0%
2.5%
amylase
0.2%
0.2%
0.2%
0.3%
lipase
0.2%
borax
1.5%
1.5%
2.4%
2.9%
calcium and sodium
0.2%
0.2%
formate
formic acid
1.1%
amine ethoxylate polymers
1.8%
1.8%
2.1%
3.2%
sodium polyacrylate
0.2%
sodium polyacrylate
0.6%
copolymer
DTPA 1
0.1%
0.1%
0.9%
DTPMP 2
0.3%
EDTA 3
0.1%
fluorescent whitening
0.15%
0.15%
0.2%
0.12%
0.12%
0.2%
agent
ethanol
2.5%
2.5%
1.4%
1.5%
propanediol
6.6%
6.6%
4.9%
4.0%
15.7%
sorbitol
4.0%
ethanolamine
1.5%
1.5%
0.8%
0.1%
11.0%
sodium hydroxide
3.0%
3.0%
4.9%
1.9%
1.0%
sodium cumene sulfonate
2.0%
silicone suds suppressor
0.01%
perfume
0.3%
0.3%
0.7%
0.3%
0.4%
0.6%
Compound 16 of Table 1
0.005%
0.005%
Compound 24 of Table 1
0.005%
Compound 13 of Table 1
0.008%
Compound 36 of Table 1
0.008%
Compound 21 of Table 1
0.015%
Liquitint Aqua AS 4
0.005%
opacifier 6
0.5%
water
balance
balance
balance
balance
balance
balance
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
1 diethylenetriaminepentaacetic acid, sodium salt
2 diethylenetriaminepentakismethylenephosphonic acid, sodium salt
3 ethylenediaminetetraacetic acid, sodium salt
4 a non-tinting dye used to adjust formula color
5 compact formula, packaged as a unitized dose in polyvinyl alcohol film
6 Acusol OP 301
Example 2
[0148] The following granular detergent formulas are within the scone of the present invention.
[0000]
2a
2b
2c
2d
Ingredient
wt %
wt %
wt %
wt %
Na linear alkylbenzene
3.4%
3.3%
11.0%
3.4%
sulfonate
Na alkylsulfate
4.0%
4.1%
4.0%
Na alkyl sulfate
9.4%
9.6%
9.4%
(branched)
alkyl ethoxylate
3.5%
type A zeolite
37.4%
35.4%
26.8%
37.4%
sodium carbonate
22.3%
22.5%
35.9%
22.3%
sodium sulfate
1.0%
18.8%
1.0%
sodium silicate
2.2%
protease
0.1%
0.2%
0.1%
sodium polyacrylate
1.0%
1.2%
0.7%
1.0%
carboxymethylcellulose
0.1%
PEG 600
0.5%
PEG 4000
2.2%
DTPA
0.7%
0.6%
0.7%
fluorescent whitening
0.1%
0.1%
0.1%
0.1%
agent
sodium percarbonate
5.0%
sodium
5.3%
nonanoyloxybenzene-
sulfonate
silicone suds suppressor
0.02%
0.02%
0.02%
perfume
0.3%
0.3%
0.2%
0.3%
Compound 15 of Table 1
0.015% 1
Compound 48 of Table 1
0.017% 2
Compound 38 of Table 1
0.017% 3
Compound 33 of Table 1
0.02% 4
water and miscellaneous
balance
balance
balance
balance
1 formulated as a particle containing 0.5% dye, 99.5% PEG 4000
2 formulated as a layered particle containing 2% dye according to US 2006 252667 A1
3 formulated as a particle containing 0.5% dye according to U.S. Pat. No. 4,990,280
4 formulated as a particle containing 0.5% dye with zeolite
Example 3
[0149] The following rinse added fabric conditioning formulas are within the scope of the present invention.
[0000]
Ingredients
3a
3b
3c
3d
Fabric Softening Active a
13.70%
13.70%
13.70%
13.70%
Ethanol
2.14%
2.14%
2.14%
2.14%
Cationic Starch b
2.17%
2.17%
2.17%
2.17%
Perfume
1.45%
1.45%
1.45%
1.45%
Phase Stabilizing
0.21%
0.21%
0.21%
0.21%
Polymer c
Calcium Chloride
0.147%
0.147%
0.147%
0.147%
DTPA d
0.007%
0.007%
0.007%
0.007%
Preservative e
5 ppm
5 ppm
5 ppm
5 ppm
Antifoam f
0.015%
0.015%
0.015%
0.015%
Compound 45 of Table 1
30 ppm
15 ppm
Compound 25 of Table 1
30 ppm
Compound 30 of Table 1
30 ppm
15 ppm
Tinopal CBS-X g
0.2
0.2
0.2
0.2
Ethoquad C/25 h
0.26
0.26
0.26
0.26
Ammonium Chloride
0.1%
0.1%
0.1%
0.1%
Hydrochloric Acid
0.012%
0.012%
0.012%
0.012%
Deionized Water
Balance
Balance
Balance
Balance
a N,N-di(tallowoyloxyethyl)-N,N-dimethylammonium chloride.
b Cationic starch based on common maize starch or potato starch, containing 25% to 95% amylose and a degree of substitution of from 0.02 to 0.09, and having a viscosity measured as Water Fluidity having a value from 50 to 84.
c Copolymer of ethylene oxide and terephthalate having the formula described in U.S. Pat. No. 5,574,179 at col.15, lines 1-5, wherein each X is methyl, each n is 40, u is 4, each R 1 is essentially 1,4-phenylene moieties, each R 2 is essentially ethylene, 1,2-propylene moieties, or mixtures thereof.
d Diethylenetriaminepentaacetic acid.
e KATHON ® CG available from Rohm and Haas Co.
f Silicone antifoam agent available from Dow Corning Corp. under the trade name DC2310.
g Disodium 4,4′-bis-(2-sulfostyryl) biphenyl, available from Ciba Specialty Chemicals.
h Cocomethyl ethoxylated [15] ammonium chloride, available from Akzo Nobel
Example 4
Synthesis of mtol-10EO methylthiazolium
[0150]
[0151] Five hundred and forty-nine grams of 85% phosphoric acid, 75 grams of 98% sulfuric acid and 9 drops of 2-ethyl hexanol defoamer are added to a 100 milliliter three necked flask equipped with a thermometer, cooling bath, and mechanical stirrer. The mixture is cooled and 30.9 grams of 2-aminothiazole is added to the flask. The mixture is further cooled to below 0° C. after which 105 grams of 40% nitrosyl sulfuric acid are added while the temperature is maintained below 5° C. After three hours the mixture gives a positive nitrite test and 25 grams of sulfamic acid are added slowly while the temperature is kept below 5° C. A negative nitrite test is evident after one hour.
[0152] A 2000 milliliter beaker is charged with 190 grams 10 EO m-toluidine intermediate, 200 grams of water, 200 grams of ice and 12 grams of urea. The mixture is cooled to 0° C. The diazo solution is added dropwise to the beaker over about 30 minutes, while maintaining the temperature below 10° C. The resulting mixture is stirred for several hours and allowed to stand overnight, after which 780 grams of 50% sodium hydroxide is added to neutralize excess acid to a pH of about 7 while the temperature is kept below 20° C. The bottom salt layer is removed and the product is washed with 200 milliliters of a 10% sodium sulfate solution. The aqueous layer is removed and the desired product is obtained as an orange liquid (240 grams, 70% actives).
[0153] One hundred grams of the orange liquid from above and 28.40 grams of dimethyl sulfate are placed into a 500 milliliter flask equipped with a reflux condenser, thermometer, heating mantle and mechanical stirrer. The reaction mixture is heated to 70° C. for two hours. The reaction is cooled and the pH is adjusted to 7 with 10 grams of 20% ammonium hydroxide and is used without further purification.
Example 5
[0154] The procedure of Example 4 is used to make N-ethyl-mtol-5EO
[0000]
[0000] with the difference being the use of the following m-toluidine intermediate:
[0000]
Example 6
[0155] The procedure of Example 5, with the noted changes, is used to make:
[0000]
[0156] Twenty grams of the orange liquid per Example 5, as obtained via Example 4, and nine grams of benzyl bromide are placed into a 250 milliliter flask equipped with a reflux condenser, thermometer, heating mantle and mechanical stirrer. The reaction mixture is heated to 70° C. for two hours. The reaction is cooled and the pH is adjusted to 7 with 4 grams of 50% sodium hydroxide and is used without further purification.
[0157] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. | The present invention relates to thiazolium dyes, laundry care compositions comprising one or more thiazolium dyes, processes of making such dyes and laundry care compositions and methods of using same. The dyes, compositions and methods of the present invention are advantageous in providing improved hueing of fabric, including whitening of white fabric, while avoiding significant build up of bluing dyes on the fabric. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to the construction, especially the lining, of furnace walls and is particularly concerned with installations utilizing blankets, bats, or blocks of relatively lightweight refractory or heat insulating materials usable at relatively high temperatures.
Many methods and devices have been previously suggested for securing refractory and/or insulating materials as linings to the interior walls of a furnace. In many of such methods or devices the lining is required to have a specific shape, or elaborate hardware on the furnace walls is required. In many instances an exorbitant amount of labor is required. Consequently, there has been a demand for a construction which permits the convenient attachment of refractory and/or insulating material in the form of blankets, sheets, bats, or blocks to furnace walls with a minimum of hardware and accessories and without exposing mounting hardware to furnace atmosphere and temperature.
It has been previously proposed to provide simple and convenient means for lining the walls by securing blankets, sheets, blocks, or bats of ceramic refractory and/or heat-insulating material on furnace walls either in a single layer or in a plurality of layers. In constructing or installing the lining the securing or mounting means may be easily applied wherever necessary or desired, thus giving a flexibility to furnace wall construction which is absent in many prior systems.
Essentially the mounting or securing devices utilized in said previous proposal consist of cup-like or truncated conical ceramic retaining members or anchors, and elongated metal studs by which the anchors are located. Each metal stud is adapted to be secured to a metal wall surface and to so engage an associated ceramic retainer as to hold it in position. More specifically, the metal studs are attached, such as by welding, to the surface of a wall to be insulated, extending essentially perpendicularly from said wall, and having such external configuration as to engage the body of refractory and/or insulating material. The truncated conical ceramic retaining members (hereinafter for convenience referred to as "anchors") may be installed with the desired spacing between them by locating the associated metal stud, forming a hole in the refractory or insulating material around the stud, inserting the anchor therein so as to engage the stud, and locking the anchor to the stud by rotating 90 degrees. The interior portion of the anchor may then be filled with a suitable refractory material so as to protect that portion of the stud projecting therein.
It is often necessary to support electrical heating elements in a furnace lined in the aforesaid manner and this has hitherto been achieved by mounting ceramic bobbins on separate, elongated metal studs secured to a metal wall surface of the furnace. This has the disadvantage that a number of extra components need to be held in stock.
It is an object of the present invention to obviate this disadvantage.
SUMMARY OF THE INVENTION
According to different aspects of the present invention there are provided:
1. A high temperature insulation construction comprising
(1) a structural supporting member,
(2) a body of insulating material superimposed over the structural supporting member,
(3) a metallic stud bearing a plurality of pairs of anchor-engaging notches, the stud being attached at one end of the stud to the structural supporting member and disposed essentially perpendicular to the structural supporting member; and
(4) an anchor positioned over the stud and engaging a first pair of notches in the metallic stud, to hold the body of insulating material between the anchor and the structural supporting member, the anchor having a cavity and being so shaped and dimensioned as to permit an identical anchor to be partially inserted within the cavity in the first anchor and engage a second pair of notches in the metallic stud, the second pair of notches being more distant from the structural supporting member than the first.
2. Such a construction, comprising in addition a removable second anchor fitted within the cavity of the first anchor, engaging the second pair of notches in the metallic stud, so as to permit supporting electrical heating elements.
3. An anchor for use in such a construction, having a tapering shank open at one end at which a radial flange provides a shoulder for trapping a body of insulating material, the other end being closed by a wall having an aperture therein for the passage of a stud, the anchor having a cavity and being so shaped and dimensioned as to permit an identical anchor to be partially inserted therein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view, partly in section, of an insulation construction according to the invention.
FIG. 2 is a sectional view of a ceramic anchor forming part of the construction shown in FIG. 1.
FIG. 3 is a perspective view of a metal stud forming part of the construction shown in FIG. 1.
FIG. 4 is an end view of the anchor and stud assembly in locked position.
FIG. 5 is a sectional view of an insulation construction according to the invention when adapted to support electrical elements.
DETAILED DESCRIPTION
The invention will now be described in detail, by way of example only, with reference to the drawings.
In FIG. 1 there is depicted in section a portion of a furnace wall, designated 10, having a body of refractory and/or insulating material 11 superimposed thereon, each of said components being effectively united and secured together by means of studs 12 and ceramic locking anchors 13. The metal stud 12, may be secured to the structure 10 by any appropriate means, such as by welds, 14, and is adjacent to the exterior or cool face of the structure, and the ceramic anchor 13 extends through and beyond the insulation surface in the direction of the interior or hot face. To facilitate the mounting and positioning of the insulating body by means of impalement upon the stud 12, the terminal end of the stud is preferably formed in a point, 15. The ceramic anchor 13, is provided with a rectangular slot 16 in the base thereof, positioned and sized to cooperate and engage with the stud 12, whereby the anchor may be slipped over the end of the stud, past the notched sections 19 thereof (see FIG. 3), and then turned through 90 degrees to form a locking engagement.
FIG. 2 illustrates the ceramic anchor 13, which is in the form of a truncated cone. The anchor comprises a high temperature resistant body having shoulders 17, which function to hold insulating material 11 in position. The ceramic anchor 13 engages the metal stud 12, by means of a rectangular slot 16, located in anchor base 22. The end of the stud then extends into the cavity, or bowl of the cup, 18.
As illustrated in FIG. 3, the metal stud 12, is substantially rectangular in cross section and has one pair of opposed sides narrower than the other pair. A plurality of pairs of discrete opposed notches 19 are disposed along the end of stud 12 opposite the welding or attachment end 20. The notches 19 are cut into the narrower sides of stud 12. The aperture 16 in the ceramic anchor 13 is of a configuration complementary with but slightly larger than the unnotched portions 21 of the rectangular stud.
During assembly, anchor 13 will be pushed downwardly over the stud 12 until the proper compression has been applied to the lining 11, as shown in FIG. 1. When this point has been reached, the anchor is then rotated through 90 degrees in the particular pair of discrete opposed notches 19 that are available at the point that aperture 16 engages the stud, as illustrated in FIG. 4. The minimum distance between the opposed walls of notches 19 is less than the minor dimension of the aperture 16 in anchor 13, and consequently less than the minor dimension of the rectangular stud 12. Additionally, the length of notches 19 is substantially greater than the thickness of anchor base 22. By this arrangement, the anchor 13 may be moved along the stud 12 to the desired notch and freely rotated to the locking position. Once the anchor has been rotated into locking position, it is then released, and the resilient force of the lining 11 will push anchor 13 against the shoulders of the opposed notch. In this manner, anchor 13 is secured against unintentional rotation. If desired, the notches may be so designed as to taper outwardly from the longitudinal axis of the stud toward the pointed end 15. In this case, the resiliency of the lining will bring the tapered walls of the notch into contact with the sides of the aperture, affording greater freedom from possible rotation.
After engagement and locking of the stud and anchor assembly the end of the stud protrudes into cavity 18 of the anchor. Since metal is subject to oxidation and deterioration at elevated temperatures, it is desirable to insulate this portion of the stud. This may be accomplished simply, by packing the cavity with a suitable refractory material. For example, bulk fiber or blanket trim may be pressed into the cavity. Alternatively, a refractory cement may be placed in the cavity, which will harden upon heating. In the preferred embodiment, the stud is proportioned so that the pointed end 15 does not extend beyond the shoulder 17 of the ceramic anchor. If the stud extends beyond the shoulders it may be cut off, by snippers for example, to ensure insulating of all metallic components of the assembly.
Various high temperature resistant materials are suitable for the practice of this invention. For example, the metal stud 13 may be prepared from such metals as stainless steels 301 and 304, or Inconel™ 601, a high solids-solution alloy commercially available from The International Nickel Company. The ceramic anchor 13 is suitably made from refractory materials such as mullite, alumino-silicate refractories, Alfrax® fused alumina refractory, or Mullfrax®, a furnace mullite refractory available from The Carborundum Company of Niagara Falls, New York. The refractory lining materials 11 may suitably be any high temperature refractory fiber blanket or felt, such as alumino-silicate fibers. A particularly suitable material is Fiberfrax® refractory fiber insulation available from The Carborundum Company of Niagara Falls, New York.
The ceramic anchors 13 are all of the same size and shape and are designated to fit one within the other in the manner shown in FIG. 5, to provide a support, generally indicated at 23, for electrical heating elements (not shown). The support 23 has the general appearance of a bobbin of which the checks or flanges are defined by the shoulders 17 of the interfitting anchors 13 and the core or reel portion is defined by a section of the tapering body portion of the inner anchor 13. The electrical heating elements are trained over the cores of the supports 23 and are retained by the check or shoulder 17 of the inner anchor 13. "Inner" and "outer" anchors 13 are designated such according to their relationship to each other. Thus the outer anchor 13 is installed first, and is closer to the furnace wall 10.
It will be appreciated that when the inner anchor 13 is removed the construction shown in FIG. 5 is substantially the same as that shown in FIG. 1, and like parts have in fact been designated by the same reference numerals and are not further described. The mounting and positioning of the insulating body proceeds as described above with reference to FIG. 1. However, when packing the cavity of any anchor 13 with a suitable refractory material as described, account must be taken of whether that particular anchor is intended to locate an inner anchor 13 so as to provide an electrical heating element support 23. If it is so intended, then the cavity of the outer anchor 13 is either left unpacked or is only packed to a limited extent compatible with location of the inner anchor 13 therein.
At those locations where a support 23 is to be provided, the tapering body portion of an inner anchor 13 is inserted into the cavity of the outer anchor 13 forming part of the attachment means for the insulating body. The extent of such insertion is obviously limited by the design and when the inner anchor 13 has been inserted to the fullest extent possible it is twisted to lock it in position on stud 12. The cavity of the inner anchor 13 may now be packed with a suitable refractory material.
As has already been indicated the support 23 is provided by two identical components, namely the inner and outer anchors 13, fitting one within the other. It will be appreciated that the inner anchor 13 could be replaced by a different component having a suitable spigot formation adapted to be received in the socket formation provided by the cavity of the outer anchor 13. While such a modification would obviously vitiate some of the advantages of the preferred embodiment described with reference to the drawings, it would nevertheless afford an improvement over the previous proposal in utilizing a pre-existing attachment site of the insulating body for the additional purpose of supporting electrical heating elements. This modification would also afford the possibility of making the core portion of the bobbin-like support 23 cylindrical rather than tapering in shape, which may prove to be an advantage. The same end may be achieved by redesigning the external shape of the anchors 13 shown in the drawings although it is preferred that the outer anchor 13 have a tapering configuration over its full length for ease of penetration into the insulating body 11.
In a further modification the notched, rectangular section studs 12 having pairs of discrete opposed notches 19 are replaced by circular section studs in which the notches are connected to form a threaded stud and the anchors are held in position by nuts.
As previously pointed out, the construction of the present invention is adapted for use in lining a furnace wall with a ceramic insulating and/or refractory body comprising one or more layers. It will be understood that in many instances there is little difference chemically between the ceramic materials used in refractory compositions and heat-insulating compositions. For example, a dense, bonded alumina body has a fairly good heat conductivity while a bonded body in which the alumina is in the form of hollow bubbles will be a good heat insulator. Accordingly, the distinction between an insulating material or composition and a refractory material or composition as used herein may reside only in the density or form of the material. In general, when a plurality of layers is used, the outer layer is primarily chosen for refractory properties, while a ceramic material having a lower heat-conductivity is employed for the inner layer. However, in some cases only a single layer of adequately insulating refractory may be used. In other cases, three or more layers of varying properties may be used if desired. The layers of insulating and/or refractory materials may be provided in a choice of forms such as bats, blankets, sheets, blocks and the like. For primarily insulating purposes blankets, bats or sheets of mineral wool or other ceramic fiber and sheets or blocks of ceramic-bonded, hollow ceramic bubbles are among the useful materials. Where a higher refractoriness is wanted denser bodies or layers are used, for example blocks of sheets of bonded alumina-silica ceramic fiber are very satisfactory. If desired, for example to make installation more convenient, a plurality of the layers of insulating and/or refractory material may be secured together by suitable means, such as a silicate cement, or even glue, but this is not essential.
The assembly of the present invention has been described in respect to its use for securing refractory linings to the walls of furnaces and the like. However, it is anticipated that the assembly may have many other uses in environments other than refractory furnaces. | There is disclosed a device for securing refractory and/or insulating material against a furnace wall. The device comprises a metal pin or stud which is attached to the wall at one end and is provided with a plurality of notched portions adjacent the other end. The stud cooperates with a hollow, preferably ceramic anchor, which is provided with a rectangular slot that fits over the notched portion of the stud and may be secured thereon by rotating an anchor through 90 degrees to effect a locking arrangement. The anchors may be interfitted in order to provide a support for electrical heating elements. The significant feature is that the size of the anchor is such as to allow another anchor to interlock and make a collar which can support electrical heating elements. As the anchor is preferably a ceramic support it is electrically insulating, and prevents the electrical heating elements from contacting the studs. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns to an automatic switching circuit of recording mode for image recording/reproducing apparatus, and more particularly to an automatic switching circuit of recording mode which, in the case of monitoring camera for recording intermittently, when motion is detected, recording mode is not only automatically switched for continued recording of pictorial images but the detection of motion is performed in oblique direction of screen.
2. Description of Prior Art
Generally, monitoring camera is widely used in various fields like those for recording situations by using in combination with video casette which can tele-record continuously images on a monitor for a long time, and for coupling image sensors to a monitor in order for video to operate automatically in accordance with the screen variations including the entry of people, and simultaneously for giving off warning sounds.
In U. S. Pat. No. 4,614,966 entitled, "Electronic still camera for generating long time exposure by adding results of multiple short time exposure", in order to prevent detection error of movement magnitude by short time exposure, a technique is introduced to prevent the detection error of movement magnitude by generating long time exposure added by data of short time exposure.
Also, U. S. Pat. No. 4,458,266, entitled "Video movement Detector" discloses a technique of detecting exact movement by dividing TV screen display into detection domain of matrix style and by integrating video signals from said domains and by detecting movement magnitude by way of comparing integrated result with previously-stored values.
However, in the conventional technical constitution as explained in the foregoing, in order to detect movement magnitude, it is inevitable to use memory, and for detection of movement magnitude by storing pixels, it has become necessary to use large capacity of memory.
Even in the case of using 1H(horizontal) retardation element CCD, the drawback of necessitating the use of large capacity of retardation element has existed for comparison between the fields.
Accordingly, it is the object of the present invention to provide automatic switching circuit of recording mode wherein, in the case of monitoring camera, intermittent recording is performed during normal times, and if movement is detected during the performance of intermittant recording, movement against 1 line of oblique direction on the screen is detected by utilizing 1H retardation element, and once movement is detected, continued recording is performed so that retardation element can be saved and simultaneously recording media can be effectively utilized.
SUMMARY OF THE INVENTION
In accordance with aspects of the present invention, there are provided various means, comprising:
pickup means for converting optical information against objects to electrical signals;
signal processing means for separating the electrical image signals of pickup means into composite image signals and luminance signals;
movement detecting means for detecting the difference between the previous field and current field against the pixel of oblique direction by receiving luminance signal from signal processing means;
comparative means for comparing movement magnitude outputted from movement detecting means with the reference value;
mode control means for switching the recording mode according to the compared value of comparative means; and
recording means for recording output signal of pickup means according to the mode switched by mode control means.
BRIEF DESCRIPTION OF THE DRAWINGS
For fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description taken in connection with the accompanying drawings in which:
FIG. 1 is a block diagram of automatic switching circuit of recording mode in accordance with the present invention;
FIG. 2 is a detailed circuit drawing as shown in FIG. 1;
FIG. 3A-3E are waveform drawings of movement as shown in FIG. 2; and
FIG. 4 is a pixel drawing of screen detected from movement detecting means adopted in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a block diagram of automatic switching circuit of recording mode in accordance with the present invention.
According to FIG. 1, pickup means 10 converts the optical information against the object into electrical signal.
Signal processing means 20 separates the electrical signals of pickup means 10 into composite image signal and luminance signal.
Movement detecting means 30 detects the difference between the previous field and present field against the pixel of oblique direction by receiving the luminance signal from signal processing means 20.
Movement discriminating means 40 compares the reference values and the movement magnitude outputted from movement detecting means 30.
Mode control means 50 switches recording mode by way of comparative values of movement discriminating means 40.
Recording apparatus 60 records the output signal of signal processing means 20 according to the mode switched by mode control means 50.
FIG. 2 is a detailed circuit diagram as shown in FIG. 1.
According to FIG. 2, signal processing means 20 includes:
a preprocessor 21 for extracting the genuine image signal out of the signals from pickup means 10;
a Y/C (luminance/chrominance signal) separator 22 for separating luminance signal from chrominance signal;
a luminance/color difference signal separator 23 for generating luminance signal and color difference signal by dint of luminace signal and chrominance signal;
an encoder 24 for generating composite image signal by way of luminance signal and color difference signal.
Movement detecting means 30 includes:
a clock generator 31 for generating pulses during scanning period of diagonal pixel on one sceen;
a first switch 32 for inputting luminance signal from signal processing means 20 by being switched by pulses outputted from said clock generator 31;
a delayer 33 for delaying the diagonal pixel of 1 horizontal line inputted by said first switch 32 until the diagonal pixel of next horizontal line is inputted; and
an operational amplifier 34 which is a difference signal amplification means for outputting by amplification the difference between the diagonal pixel delayed by said delayer 33 and the currently-inputted diagonal pixel.
Movement discriminating means 40 includes;
first & second comparators 41, 42 which are comparative means for comparing the movement signal outputted from movement detecting means 30 with reference level; and
a first gate 43 for outputting movement discriminating signal by way of the output of said first & second comparators 41, 42 when movement signal is above the reference level.
Recording mode control means 50 includes:
an intermittent tele-recording timer 53 for generating tele-recording start signal in predetermined interval;
a second switch 51 for switching the input of movement discriminating signal outputted from movement discriminating means 40 according to the pulses generated from movement detecting means 30;
signal preservation means of T F/F(Toggle Flip/Flop) 52 for preserving movement discriminating signal to prevent movement discriminating signal from being changed within the switching period; and
a second gate 54 for controlling the tele-recording of recording apparatus in accordance with the outputs of said intermittent tele-recording timer 53 and T F/F(52)
With reference to the movement waveform drawings as shown in FIGS. 3A-3E and the pixel drawing of screen detected from movement detecting means 30 as shown in FIG. 4, above-mentioned construction is explained in detail as below.
The optical information against the objects incident from camera lens(not shown) extracts the charges photoelectric-converted from CCD (Charged Coupled Device) of pickup means 10.
In this location, pickup means 10 comprises CCD for converting optical information against the objects into electrical signal for accumulation and CCD driving circuit for reading out photoelectric charge accumulated for a time period corresponding to shutter speed by adding scanning pulse to each pixel of CCD.
Preprocessor 21 of signal processing means 20 performs CDS(Coefficient Double Sampling) in order to extract genuine image signal out of photoelectric-converted signals outputted from said pickup means 10.
Y/C separator 22 separates image signals outputted from said preprocessor 21 into luminance signal Y and chrominace signal C for outputting to luminance/color difference separator 23.
At this moment, luminance signal Y is also supplied to movement detecting means 30.
Said luminance/color difference separator 23 is composed of matrix and separates the output signal of Y/C separator 22 into luminance signal Y and color difference signals R-Y, B-Y.
Encoder 24 encodes said luminance signal Y and color difference signals R-Y, B-Y and outputs to recording apparatus 60 in composite image signals.
Meanwhile, the delayer 33 of movement detecting means 30 is short-circuited according to the clocks outputted from clock generator 31 and delays by 1 field the luminance signal Y of said Y/C separator 22 inputted through the first switch 32, which implies, delays by 1 vertical period.
At this point, delayer 33 is composed of 1H delaying element or a shift register, and in the case of using CCD delaying element, 1 horizontal line is 201.5 clocks and frequency is around 4 MHZ at driving clock of 1H CCD delaying element as illustrated in FIG. 3A.
At this moment, as the vertical perod, in the case of NTSC(National Television System Committee), is 525/2=262.5H, as depicted in FIG. 3B, the blanking period from vertical driving pulse of 1V=262.5H is assumed 61H as illustrated in FIG. 3C. And as illustrated in FIG. 3D, 1H CCD driving clock is counted in 202.5 clock period for generation of driving output, thus controlling the first switch 32, delayer 33, second switch of mode controller 50 and T F/F 52, then pixel on screen increasing per 1 clock during the increase of 1 horizontal line is selected.
Furthermore, at clock generator 31, as illustrated in FIG. 3E, vertical driving pulse having 1 vertical period 1V of 201.5 clocks is generated, and first switch 31, delayer 33, second switch 51 and T F/F are controlled.
Accordingly, in the final output outputted from the delayer 33, as depicted in FIG. 4, pixel of diagonal direction on the screen is delayed by 1 vertical period for outputting, and the output signal of said delayer 33 is adjusted in level by a variable resistor 35 for input into non-inversion terminal of operational amplifier.
In inversion terminal of said operational amplifier 34, the luminance signal Y of diagonal direction of screen against the current field outputted from Y/C separator 22 of signal processing means 20 is switched to signal period by the first switch 32 as illustrated in FIG. 3D and thereafter inputted.
Accordingly, in the operational amplifier 34, the difference signal between the pixel of diagonal direction delayed by delayer 33 and the pixel of diagonal direction against the current field, in other words, the signal in accordance with the movement magnitude is amplified for output.
The difference signal outputted from said operational amplifier 34 is inputted to movement discriminating means 40.
When the difference signal is inputted to movement discriminating means 40, the outputs of said operational amplifier 34 are compared with predetermined reference levels, ref 1, ref 2, by a source voltage Vcc and resistors R1, R2, R3 at first & second comparators 41, 42.
At the first gate 43, when the signal according to the movement magnitude outputted from said operational amplifer 34 lies in between reference levels, ref 1, ref 2, the logic signal of low state is outputted. When above the reference level, ref 1 or below reference level, ref 2, logic signal of high state is outputted.
In other words, the first comparator 41 discriminates whether or not difference signal is above the reference level, ref 1 when the luminance signal value of delayed diagonal direction of pixel is larger than the luminance signal value of diagonal direction against the current field and the second comparator 42 discriminates whether or not difference signal is above the reference level, ref 2 when the luminance signal value of pixel of diagonal direction against the current field is larger than the luminance signal value of pixel of delayed diagonal direction. And accordingly, when difference signal outputted from operational amplifier 34 of movement detecting means 30 is above the reference level, ref 1, the first comparator outputs logic signal of high state, and the second comparator outputs logic signal of low state.
When the difference signal outputted from operational amplifer 34 is below the reference level, ref 2, the first comparator 41 outputs logic signal of low state and the second comparator 42 outputs logic signal of high state. At this moment, the first gate 43 outputs logic signal of high state.
In this manner, when the variation degree of screen is above the reference value, the output of first gate 43 becomes logic signal of high state, and through the second switch 51 of mode controller 50 and T F/F 52 controlled by clock generator 31 of movement detecting means 30, is supplied to the second gate 54, causing the output of second gate 54 to become logic level of high state. The output signal of second gate 54 is applied to tele-recording control terminal REC of recording apparatus 60.
Accordingly, the recording apparatus 60 records continuously the output signal of said processing means 20.
When the variation degree of screen is below the reference value, in other words, when the output of said operational amplifier 34 is below predetermined reference value, as the output of operational amplifier 34 is smaller than the reference level, ref 1 and larger than the reference level, ref 2, logic level of signal in low state is outputted from the first gate 43 and inputted to the second gate 54.
At this point, the recording apparatus 60 tele-records or does not tele-record the composite image signal outputted from signal processing means 20 according to the output signal of intermittent tele-recording set-up timer 50 in mode controller 50.
At the second gate 54 of mode controller 50, the logic level signals of high and low states are outputted by set-up interval outputted from intermittent tele-recording time set-up timer 53, and recording apparatus 60 records periodically the composite image signal outputted from encoder 24 of signal processing means 20.
In other words, assuming that set-up interval is one minute, as logic level signals of high and low states are outputted in one minute period at intermittent tele-recording timer 53, one minute of high state and one minute of low state of logic level signals are applied to tele-recording control terminal REC of recording apparatus 60 through the second gate 54, causing the recording apparatus 60 to record composite image signal in every one minute period.
At this moment, as T F/F 52 is the same as the period of first & second switches 32, 51, in order to prevent the output of first gate 43 from changing within switching period, the first switch 32 maintains the output of first gate 43, namely, the compared value of the first & second comparators 41, 42, in every switching moment.
As from the foregoing, the automatic switching circuit of recording mode in accordance with the present invention, utilizing 1H delaying element, can simplify the circuit, perform continued filming only in case of necessity and obtain the effect of saving recording media by controlling intermittent/continued recording by virtue of detection of movement, namely, the detection of the difference of pixel between the previous field and current field in diagonal direction of screen, causing the lessened capacity of delaying element.
The foregoing description of the preferred embodiment has been presented for the purpose of illustration and description. Many modifications and variations are possible in light of above teaching, and specifically by the control of pulses generated from clock generator, one line of diagonal direction detected from movement detecting means can be moved from the right upper end of screen toward the left lower end in diagonal direction, or pixel signal from upper end to any lower vertical line, or pixel signal from left to right in any horizontal line can be detected, and it will be understood by one of ordinary skill in the art that various modification can be made, without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims. | An automatic switching circuit of recording mode in an image recording and reproduction apparatus, and wherein, when the image recording apparatus is recording intermittently and movement is detected, the recording mode is automatically switched for continued recording of pictorial images. This results in the conservation of recording media and saves delaying element by performing the detection of movement in the diagonal direction of a screen. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to system level computer operation, and more specifically, to security measures to protect computer systems.
2. Description of the Related Art
As the computer industry has evolved, computers have become smaller and more portable. Reductions in size, power and other considerations, as well as diminution of chip size and migration of multi-chip functionality to a single chip have resulted in computers that are light weight, easy to use, and easy to transport. Given the highly mobile nature of portable computers and their usage, the trend toward more portable computer systems is likely to accelerate.
While the increased portability of small computer systems has generated tremendous advantages for the computer industry as well as for computer users, the risk of lost or stolen computer systems presents a continuing problem. Often without malicious intent, computer users inadvertently pick up a computer system belonging to another person or company. Moreover, even within the computer industry, employees often take small computers home in the evening or on weekends to work. Inevitably, problems arise as to the proper custody or ownership of a particular computer system.
Such problems do not only exist between separate entities. Even within a company, each department may be allotted a particular group of computer systems, and computer systems from other departments may inadvertently be carried into the area. Confusion may arise as to which computers belong to which area.
In addition to loss or theft of the physical computer system, intellectual property issues can also become implicated. Proprietary information loaded onto a computer system can be difficult to remove completely since various traces of deleted information often remain on a hard disk. When computer systems are indistinguishable, it may be difficult to insure that such information has been properly deleted from a computer system. Computer systems that have previously stored highly sensitive information may inadvertently fall into the hands of those not cleared for the information, perhaps jeopardizing confidentiality.
Physically marking a computer system, for example by engraving or otherwise marking the exterior of the computer case, has significant disadvantages. With respect to the innocent switching of computer systems, permanently marking the exterior of a computer case can make computer systems very difficult to reallocate. Because the needs for computers within a company can evolve over time, companies must be free to reallocate computers among various departments as needs arise. Therefore, permanently marking computer systems may be disadvantageous. With respect to the malicious theft of computer systems, permanently marking the exterior of a computer case does not prevent a thief from merely covering the exterior marking, or from replacing the computer case with another computer case and attempting to resell the computer. Therefore, the difficulties inherent in computer system identification are not solved by marking the case or cover.
SUMMARY OF THE INVENTION
Briefly, the present invention provides a new and improved identification technique for computer system. The present invention allows a computer administrator or other trusted person to place a “ownership tag” in a special area of memory that cannot be altered without the use of a special administrator password. The ownership tag indicates the person or entity who presently has the right of custody of the computer system. When a user powers on the computer system, the ownership tag is presented to the user. For example, the ownership tag is preferably presented during the installation and execution of the Power on Self Test (POST) portion of the Basic Input Output System or BIOS.
With the present invention, the POST processes can be interrupted. The POST process are interrupted by a user pressing a suitable key during the normal POST routine. Interruption of the POST process allows the computer to enter an administrator set up mode. In the administrator set up mode, a system administrator may enter the administrator password and alter the contents of the protected memory, changing the ownership tag. Additionally, the system administrator can if desired alter the ownership tag remotely over a network.
According to the present invention, the administrator may enter a special administrator password in order to alter the ownership tag. If desired, the computer system may be set so that a person must physically remove the memory device containing the ownership tag, place the ownership tag memory in an external device that is not part of the computer system, and apply external voltages and currents not available within the computer system to the memory in order to change the ownership tag.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention can be obtained when the following detailed description of the preferred embodiment is considered in conjunction with the following drawings, in which:
FIG. 1 is a schematic block diagram of a computer system according to the present invention.
FIG. 2 is a schematic diagram of flash ROM components of the computer system of FIG. 1 .
FIG. 3 is a schematic diagram of a video card and portions of the audio card of the computer system of FIG. 1 .
FIG. 4 is a block diagram of components initialized by a boot block in the computer system of FIG. 1 .
FIG. 5 is a schematic diagram of components of the computer system of FIG. 1 having multiple slots for connecting memory devices.
FIG. 6 is a flow chart of POST execution according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following disclosures are hereby incorporated by reference:
U.S. application Ser. No. 09/071,127, entitled “A COMPUTER METHOD AND APPARATUS TO FORCE BOOT BLOCK RECOVERY,” by Don R. James, Jr., Randall L. Hess, and Jell D. Kane, filed Apr. 30, 1998, U.S. Pat. No. 6,363,492, issued Mar. 26, 2002;
U.S. application Ser. No. 09/070,821, entitled “BOOT BLOCK SUPPORT FOR ATAPI REMOVABLE MEDIA DEVICES,” by Paul J. Broyles III, and Don R. James, Jr., filed Apr. 30, 1998, abandoned;
U.S. application Ser. No. 09/070,475, entitled “SECURITY METHODOLOGY FOR DEVICES HAVING PLUG AND PLAY CAPABILITIES,” by Christopher E. Simonich and Robin T. Tran, filed Apr. 30, 1998, U.S. Pat. No. 6,301,665, issued Oct. 9, 2001;
U.S. application Ser. No. 09/070,942, entitled “METHOD AND APPARATUS FOR REMOTE ROM FLASHING AND SECURITY MANAGEMENT FOR A COMPUTER SYSTEM,” by Manuel Novoa, Paul H. McCann, Adrian Chrisan. and Wayne P. Sharum, filed Apr. 30, 1998, U.S. Pat. No. 6,223,284, issued Apr. 24, 2001;
U.S. application Ser. No. 09/070,866, entitled “A METHOD FOR FLASHING ESCD AND VARIABLES INTO A ROM,” by Mark A. Piwonka, Louis B. Hobson, Jeff D. Kane, and Randall L. Hess, filed Apr. 30, 1998, U.S. Pat. No. 6,073,206, issued Jun. 6, 2000;
U.S. application Ser. No. 08/684,413, entitled “FLASH ROM PROGRAMMING,” by Patrick R. Cooper, David J. Delide, and Hung Q. Le filed Jul. 19, 1996, U.S. Pat. No. 5,805,882, issued Sep. 8, 1998;
U.S. application Ser. No. 09/071,128, entitled “A UNIFIED PASSWORD PROMPT OF A COMPUTER SYSTEM,” by Michael D. Garrett, Randall L. Hess, Chi W. So, Mohammed Anwarmariz, filed Apr. 30, 1998, U.S. Pat. No. 6,397,337, issued May 28, 2002;
U.S. application Ser. No. 09/123,307, entitled “COMPUTER SYSTEM WITH POST SCREEN FORMAT CONFIGURABILITY, by Rahul Patel and Paul J. Broyles III, filed Apr. 12, 2001; and
U.S. application Ser. No. 09/123,672, entitled “METHOD FOR STORING BOARD REVISION,” by Paul J. Broyles III and Mark A. Piwonka, filed Jul. 28, 1998, U.S. Pat. No. 6,405,311, issued Jun. 11, 2002; all of which are assigned to the assignee of this invention.
Computer System Overview
Turning to FIG. 1, illustrated is a typical computer system S implemented according to the invention. While this system is illustrative of one embodiment, the techniques according to the invention can be implemented in a wide variety of systems. The computer system S in the illustrated embodiment is a PCI bus/ISA bus based machine, having a peripheral component interconnect (PCI) bus 10 and an industry standard architecture (ISA) bus 12 . The PCI bus 10 is controlled by PCI controller circuitry located within a memory/accelerated graphics port (AGP)/PCI controller 14 . This controller 14 (the “host bridge”) couples the PCI bus 10 to a processor socket 16 via a host bus, an AGP connector 18 , a memory subsystem 20 , and an AGP 22 . A second bridge circuit, a PCI/ISA bridge 24 (the “ISA bridge”) bridges between the PCI bus 10 and the ISA bus 12 .
The host bridge 14 in the disclosed embodiment is a 440LX Integrated Circuit by Intel Corporation, also known as the PCI AGP Controller (PAC). The ISA bridge 24 is a PIIX4, also by Intel Corporation. The host bridge 14 and ISA bridge 24 provide capabilities other than bridging between the processor socket 16 and the PCI bus 10 , and the PCI bus 10 and the ISA bus 12 . Specifically, the disclosed host bridge 14 includes interface circuitry for the AGP connector 18 , the memory subsystem 20 , and the AGP 22 . The ISA bridge 24 further includes an internal enhanced IDE controller for controlling up to four enhanced IDE drives 26 , and a universal serial bus (USB) controller for controlling USB ports 28 .
The host bridge 14 is preferably coupled to the processor socket 16 , which is preferably designed to receive a Pentium II processor module 30 , which in turn includes a microprocessor core 32 and a level two (L2) cache 34 . The processor socket 16 could be replaced with different processors other than the Pentium II without detracting from the spirit of the invention.
The host bridge 14 , when the Intel 440LX Host bridge is employed, supports extended data out (EDO) dynamic random access memory (DRAM) and synchronous DRAM (SDRAM), a 64/72-bit data path memory, a maximum memory capacity of one gigabyte, dual inline memory module (DIMM) presence detect, eight row address strobe (RAS) lines, error correcting code (ECC) with single and multiple bit error detection, read-around-write with host for PCI reads, and 3.3 volt DRAMs. The host bridge 14 support up to 66 megahertz DRAMs, whereas the processor socket 16 can support various integral and nonintegral multiples of that speed.
The ISA bridge 24 also includes enhanced power management. It supports a PCI bus at 30 or 33 megahertz and an ISA bus 12 at ¼ of the PCI bus frequency. PCI revision 2.1 is supported with both positive and subtractive decode. The standard personal computer input/output (I/O) functions are supported, including a dynamic memory access (DMA) controller, two 82C59 interrupt controllers, an 8254 timer, a real time clock (RTC) with a 256 byte complementary metal oxide semiconductor (CMOS) static RAM (SRAM), and chip selects for system read only memory (ROM), real time clock (RTC), keyboard controller, an external microcontroller, and two general purpose devices. The enhanced power management within the ISA bridge 24 includes full clock control, device management, suspend and resume logic, advanced configuration and power interface (ACPI), and system management bus (SMBus) control, which implement the inter-integrated circuit (I 2 C) protocol.
The PCI bus 10 couples a variety of devices that generally take advantage of a high speed data path. This includes a small computer system interface (SCSI) controller 26 , with both an internal port 38 and an external port 40 . In the disclosed embodiment, the SCSI controller 26 is a AIC-7860 SCSI controller. Also coupled to the PCI bus 10 is a network interface controller (NIC) 42 , which preferably supports the ThunderLan™ power management specification by Texas Instruments. The NIC 42 is coupled through a physical layer 44 and a filter 46 to an RJ-45 jack 48 , and through a filter 50 to a AUI jack 52 .
Between the PCI Bus 10 and the ISA Bus 12 , an ISA/PCI backplane 54 is provided which include a number of PCI and ISA slots. This allows ISA cards or PCI cards to be installed into the system for added functionality.
Further coupled to the ISA Bus 12 is an enhanced sound system chip (ESS) 56 , which provides sound management through an audio in port 58 and an audio out port 60 . The ISA bus 12 also couples the ISA bridge 24 to a Super I/O chip 62 , which in the disclosed embodiment is a National Semiconductor Corporation PC87307VUL device. This Super I/O chip 62 provides a variety of input/output functionality, including a parallel port 64 , an infrared port 66 , a keyboard controller for a keyboard 68 , a mouse port for a mouse port 70 , additional series ports 72 , and a floppy disk drive controller for a floppy disk drive 74 . These devices are coupled through connectors to the Super I/O 62 .
The ISA bus 12 is also coupled through bus transceivers 76 to a flash ROM 78 , which can include both basic input/output system (BIOS) code for execution by the processor 32 , as well as an additional code for execution by microcontrollers in a ROM-sharing arrangement.
The ISA bus 12 further couples the ISA bridge 24 to a security, power, ACPI, and miscellaneous application specific integrated circuit (ASIC) 80 , which provides a variety of miscellaneous functions for the system. The ASIC 80 includes security features, system power control, light emitting diode (LED) control, a PCI arbiter, remote wake up logic, system fan control, hood lock control, ACPI registers and support, system temperature control, and various glue logic.
Finally, a video display 82 can be coupled to the AGP connector 18 through an AGP master or video card 150 for display of data by the computer system S. The video display 82 displays video and graphics data provided by a video display process running on either the processor module 30 or another by a PCI device bus master or PCI bridge device bus master via host bridge 14 . Video or graphics data may be stored in main memory or in a supplementary or extension memory module. Again, a wide variety of systems could be used instead of the disclosed system S without detracting from the spirit of the invention.
According to the present invention, certain memory locations having additional protection from alteration, such as indicated at 202 in flash ROM 78 , contain an ownership tag. The ownership tag 40 stored identifies the owner or person presently authorized custody or allocation of computer system S. When processor module 30 is booted, a basic input output system (BIOS) is loaded and executed on processor module 30 . According to the present invention, the processor associated with the BIOS obtains the ownership tag from the protected area of memory and displays the ownership tag on display 82 .
The ownership tag display may be of any suitable form and content consistent with the amount of protected area of memory allocated for this purpose. The ownership tag, identifies the person or business unit or entity which is the presently authorized owner or custodian of the computer system S. The ownership tag may identify an individual person or business entity who is the owner of the computer system, or it may identify a section or group within a company which is the currently authorized custodian of the computer system. Again, the format in which the tag is displayed is selected by the authorized administrator, based in part on the amount of memory allocated for this purpose.
The Flash ROM Boot Block
Turning now to FIG. 2, a sector partitioning structure 200 of the flash ROM 78 in the disclosed embodiment is shown. However, while this diagram is illustrative of one embodiment, the techniques according to the invention can be implemented in a variety of embodiments and can be implemented with a variety of non-volatile memory. The sector partitioning structure 200 is determined by the sector architecture of the particular flash ROM 78 . The flash ROM 78 used in the disclosed embodiment is an Advanced Micro Devices (AMD) AM29F002 type flash ROM memory. The sector partitioning structure 200 shows a top boot block design architecture. The Advanced Micro Devices AM29F002 flash ROM memory can also be implemented with a bottom boot block design architecture.
A boot block sector 202 consists of a first boot block sector 204 of 16 kilobytes and a second boot block sector 206 of 8 kilobytes. The remaining 232 kilobytes form a system block 208 divided into 5 sectors 210 - 218 . In the disclosed embodiment, the first sector 210 has 8 kilobytes, the second sector 212 has 32 kilobytes, and the remaining three sectors 214 , 216 , and 218 have 64 kilobytes equally.
The code stored in the system block 208 preferably contains the Basic Input/Output System (BIOS) code. The BIOS is code interfacing between the operating system and the specific hardware configuration, allowing the same operating system to be used with different hardware configurations. The boot block 202 contains the code necessary to initialize the systems when an anomaly during power-up is detected. During a boot block 202 initialization, preferably a reduced set of hardware is initialized, thus reducing the size of the code in the boot block 202 . The boot block 202 code typically contains an initialization procedure for only the hardware necessary to perform limited functions. Typically a limited function necessary to be performed during boot block 202 initialization is the flash of the ROM 78 .
The boot block 202 , according to the invention, contains code initializing the hardware components necessary to flash the ROM 78 and to prompt the user for an administrative password. The boot block 202 code is contained within the boot block 202 , which is protected from spurious initialization.
The boot block 202 is stored in a region or protected area of memory not available to the user. Such a protected area may, if desired, be a flash memory which must be physically removed to be reprogrammed. A person must physically remove the boot block 202 and place that memory device in an external device to the computer system to reprogram it. Further, such a memory device is preferably one which for reprogramming requires voltage or current devices not available within the computer system S.
The system block 208 is electronically protected, but the system S is at least physically capable of disabling that protection and overwriting the system block 208 . During a flash, the system block 208 sectors may be rewritten with a new flash ROM image.
The flash ROM 78 is a 256 KB ROM that also supports a 24 KB boot block. The flash ROM 78 , upon system initialization, creates a ROM image in RAM when the ROM image becomes corrupted or otherwise unsatisfactory. The flash ROM 78 uses nonvolatile (NV) RAM to check the image and to determine whether the ROM image, stored in RAM is valid. If the image is bad, the ROM boots from the boot block rather than from the image. The NVRAM and ROM contain logic to select a memory subsystem mode, such as factory mode, normal mode, and administrator mode. Depending on the level of security required, different information stored may be stored in this memory for display at selected times during operation of the computer system S. With the present invention, the ownership tag is protected at an administrator mode level.
The boot block 202 contains an additional portion of ROM code within the ROM 78 that is executed at system reset. The boot block code contains a validation portion and a boot portion. Upon system reset, the validation portion performs a validation check on the system ROM 78 itself and either jumps to the normal system ROM code or to the boot portion, depending upon the result of a validation check. The boot portion, although not capable of initializing any add-in devices except IDE's, does contain enough code to allow a system administrator to flash a valid ROM code into ROM 78 from a diskette. The boot block is physically located within the ROM to be accessed by the reset vector.
The flash ROM 78 as has been mentioned, may be an AMD29F002T, which contains a 16 KB sector, two 8 KB sectors, a 32 KB sector, and three 64 KB sectors. The boot block occupies the first two sectors (totaling 24 KB), and is followed by an 8 KB ESCD sector, a reserved 32 KB sectors, a 64 KB sector containing normal-mode ROM code, 64 KB of compressed data, and 64 KB of CPU BIOS update code. The boot block 202 code typically is small in relation to the system block 208 code. According to the present invention, the ownership tag is stored in an administrator password protected area of flash ROM.
In the preferred embodiment, the memory sector with the ownership tag is not protected by the boot block hardware. Rather, the ownership tag is in a different sector of the flash ROM 78 , one which is protectable by administrator password. This is described below.
Turning to FIG. 3, a schematic diagram of a typical AGP master or video card 150 and portions of the audio card 154 (FIGS. 1 and 3) of the computer system S is shown. The inputs to the video card 150 include three composite video signals provided through Y 1 C video connectors, composite_ 1 302 , composite_ 2 304 , and composite_ 3 306 . The constituent signals of the three input composite signals are provided to a pair of video multiplexers 308 and 310 . A chrominance signal on line 312 from the composite_ 1 signal 302 is provided to video multiplexer 310 , and a luminance signal on line 314 of the composite_ 1 signal 302 is provided to video multiplexer 310 . The chrominance signal on line 316 of the composite_ 2 signal 304 is provided to video multiplexer 308 , and a luminance signal on line 318 of the composite_ 2 signal is provided to video multiplexer 310 . The composites_ 3 signal 306 includes a luminance signal on line 320 which is provided to video multiplexer 308 . Tuners 322 and 324 located on the audio card 154 of the computer system S also provide input luminance signals on lines 328 and 330 to video multiplexer 310 . Other conventional devices that are provided on the audio card 154 are not shown as the audio card 154 as they are not critical to an understanding of the present invention.
A signal on line 332 outputted from video multiplexer 308 is provided to a primary analog video multiplexer 334 . Video multiplexer 308 also provides a Y/C signal on line 336 to a secondary analog video multiplexer 338 . Video multiplexer 310 provides signals on lines 340 and 342 ; the signal on line 342 is provided to the primary analog video multiplexer 334 , and the signal on the other line 340 is provided to the secondary analog video multiplexer 338 . The analog video multiplexer 334 is integrated into a primary video composite decoder 344 , and the secondary analog video multiplexer 338 is integrated into a secondary video composite decoder 346 . The primary decoder 344 of the present invention may or may not include color separation circuitry, as desired.
The video card 150 of the computer system 10 of the present invention includes color separation circuitry 348 external to the primary decoder 344 . The color separation circuitry 348 receives a composite signal on line 350 as an input from video multiplexer 308 and outputs a chrominance signal on line 352 and a luminance signal on line 354 to the primary analog video multiplexer 334 of the primary decoder 344 . The color separation circuitry 348 includes a digital comb filter, by which video information is converted from analog to digital and back to analog. The video signal from decoder 344 is provided on line 358 a digital video multiplexer 360 . Similarly, an output video signal on line 262 of the secondary video composite decoder 346 is provided to a digital video multiplexer 364 .
The primary digital video multiplexer 360 provides two outputs, on lines 266 and 268 . The output on line 266 is provided directly to the VGA subsystem 370 . The output on line 268 is directed to a phase-locked-loop 372 (PLL). The PLL 372 supplies a clock signal on line 324 to the VGA subsystem 370 . The VGA subsystem 370 has two memory areas; one area is used as an off-screen memory area for storing video information, such as font information and data yet to be displayed. The other memory area of VGA subsystem 370 is used to store data which is currently being displayed. The VGA subsystem 370 also includes a VGA controller. In displaying data, the VGA controller reads from the off-screen memory, scales the data if needed, performs color space conversion, and then sends the data through a digital-to-analog converter (DAC) to the display.
In the secondary path, the secondary digital video multiplexer 364 provides a signal on line 276 to a video scaler and PCI bus interface 378 . When data is sent over the secondary path, the data is downscaled if needed and then burst over the PCI bus 120 into the off-screen memory area of the video memory. The secondary path is typically used for picture-in-picture (PIP) functionality or pulling up web pages while watching television on the display 82 which are encoded in the vertical blanket interval (VBI).
Therefore, typically, the video display device 82 is a primary output device that cannot be turned off during the BIOS. The display screen 82 is always active, and is always capable of presenting an image provided to it. Various peripheral devices can attempt to control the video display during the BIOS, since the operating system has not been loaded and launched and thus cannot control the peripherals.
Turning to FIG. 4, illustrated is a block diagram 400 of components of the system S that are initialized by the boot block 202 . The processor 32 copies the system block code 208 from the ROM 78 into RAM, creating the ROM image, and then executes the system block 208 code, including the boot block 202 code contained in the ROM image. The processor 32 , during initial power up and execution of boot block 202 code, executes the validation portion to determine if the flash ROM 78 has become corrupt. If the flash ROM 78 is corrupt, then the processor 32 executes the boot portion of the boot block to allow an administrator to re-flash portions of the boot block 202 code from a diskette. Also, during initial power up, when reflashing is not needed, the Super I/O device 62 and the security device 80 are initialized by the processor 32 . BIOS code is also loaded from the ROM or NVRAM into RAM.
Whichever boot code the validation portion determines to use is loaded into NVRAM (nonvolatile memory) within the black box or security device 80 (FIGS. 1 and 5 ). The NVRAM is faster than the ROM itself. When power is applied to the system, the BIOS is booted from the ROM, either via the image or the NVRAM. The BIOS then attempts to complete system initialization in normal mode unless interrupted during initialization. BIOS execution continues from the NVRAM and, upon conclusion, launches the operating system. The NVRAM and black box may also reside in a dedicated chip or device, or may reside in the Super I/O 62 .
The NV RAM Black Box
Turning now to FIG. 5, black box or security device 80 and NV RAM of the super I/O chip 62 are shown in greater detail. The black box 20 is nonvolatile RAM (NVRAM) that is composed of CMOS, yet is accessible only to the BIOS and the operating system (not to any other software running on the computer system). An unauthorized user, or one not possessing the appropriate administrative password, cannot access the location of the CMOS containing the ownership tag. The black box is a protected region within the NVRAM that is writeable only by the BIOS, and readable only by the BIOS and by the operating system. NVRAM is typically provided with back-up batteries to prevent power loss. The BIOS accesses the CMOS by generating an Int 15 h followed by the location within CMOS and, if the access is write enabled, data to be written to the CMOS location. This process is described below with respect to boot access to the ownership tag.
The memory security device 80 of FIG. 5 functions to lock and unlock resources within the computer system S, having multiple slots for connecting memory devices. The memory security device 80 of FIG. 4 includes three slots, numbered 0 through 2 , each protected according to a different methodology. The contents of the memory devices connected to each security device 80 are accessible only to memory access requests complying with the corresponding methodology. Each slot of device 80 has two states: a locked state, in which data is protected, and an unlocked state. In the locked state, access is denied to the memory device connected to the corresponding slot. To transition to the locked state, a user must enter a “protect resources” command. To transition to unlocked state, transitioning the slot from the locked state, an “access resources” command must be issued, followed by a correct password.
Slot 0 of device 80 includes a flash ROM interface connecting to a flash ROM device, such as flash ROM 78 . Slot 0 is the factory made protection level. It protects the flash ROM 78 from unauthorized writes such as viruses and unauthorized individuals. At power-up, the BIOS loads a flash ROM password into slot 0 and executes the “protect resources” command for that slot. After the system S has completed the boot process and before any other software is loaded, the BIOS issues a “protect resources” command to slot 0 , disabling further access to the flash ROM 78 .
Slot 1 of device 80 contains the “power-on” password of the user. The security device 80 communicates with the super I/O chip 62 containing the CMOS, by holding an “SIOAEN” and/or a “SIOWCL” signal to keep the super I/O chip 62 from decoding read and/or write cycles to the “power-on” password locations in the CMOS. The AEN signal is derived from ANDing a signal indicating that the black box slot 1 is locked and a signal indicating that the last data write to a real time clock index register was in the “power-on” password range, indicating that the user has missed an opportunity to access the “power-on” password location. Thus, the security device 80 controls access to the CMOS within the super I/O chip 62 . The slot 1 of the black box selectively disables access to the “power on” password storage area 502 within the CMOS. In contrast, the SIOWCL signal operates similarly to the SIOAEN signal, although the SIOWCL signal only prohibits writes and does not prohibit reads to the password. Thus, the SIOWCL signal may be used during subsequent user sessions to determine whether the user password has been entered correctly.
Slot 2 of the security device 80 is accessible only with an administrator password. The limited access of the slot 2 memory device protects system resource information that must be protected to preserve the integrity of the computer system. The administrator password is necessary to access particular registers of CMOS region 504 . As has been noted, the ownership tag of the computer system S according to the present invention is stored in region 504 . The unlocking of slot 2 , however, also unlocks slot 1 , allowing an administrator cognizant of the administrator password to access these CMOS locations. Thus, the administrator has control of these memory locations in the computer system. It is recommended that, prior to unlocking slot 2 , the administrator check the status of slot 1 to see if it is locked, since relocking slot 2 does not re-lock slot 1 .
The ownership tag can also be secured without the black box 80 . In some implementations, the black box 80 can be used to store the ownership tag and increase the security level. However, this is not required. As has been noted, the ownership tag is protected as a minimum normally by administrator password.
According to the present invention, the ownership tag is preferably displayed during the POST routine for the computer system S. FIG. 6 in the drawings illustrates a flow chart of those steps which accomplish he display of the ownership tag on the display 82 . As will be noted, the ownership tag may be displayed as a routine portion of the normal POST routine, or alternatively may be changed by an authorized administrator and then subsequently displayed. The remaining portions of the POST process are conventional and are depicted, for example, in co-pending U.S. application Ser. No. 09/123,307, “COMPUTER SYSTEM WITH POST SCREEN FORMAT CONFIGURABILITY,” filed Apr. 12, 2001.
During the conventional POST process, a step 600 occurs when the error interrupts and interrupts from the keyboard 68 are enabled. At this point the display of the ownership tag according to the present invention occurs Normally, a step 602 assumes operation of the computer system S during the POST process and causes the ownership tag to be transferred from location 202 in the flash ROM 78 and transferred into a suitable RAM memory location in the computer system S. Thereafter, during step 604 , the ownership tag is transferred from the RAM memory location into a video buffer in the video card 150 during a step 604 . Thereafter, during step 606 , the ownership tag contained in the video buffer is displayed on the display 82 during a step 606 , from which control of the computer system S reverts back to the remaining portions of the conventional POST process described in the co-pending application mentioned above.
This is done by a user depressing a suitable key, generating a keyboard interrupt during step 610 . Thereafter, during a step 612 , the computer system S prompts the user for the administrator password required for access to slot 2 of the security device 80 in order to access region 504 of CMOS memory containing the administrator password. If the proper administrator password is received, the ownership tag stored in slot 2 of the security device 80 may be modified during a step 614 . If an improper password is attempted during step 612 , access to the slot 2 of the security device 80 is prohibited. After the ownership tag is received during step 614 , control of the computer system S transfers to step 602 and display operations continue in the manner previously described.
An example code for retrieving and displaying the ownership tag according to the present invention is set forth below:
dpaintOwnershipTag - Draws the ownership tag onto clean screen.
Entry:
None
Exit:
Ownership tag is visible on the clean screen.
Regs:
Flags
dPaintOwnershipTag proc near
push
dx
push
bx
mov
dh,COWNERTAG_ROW
; DH = Row to display string
mov
bx, (CSCREEN_PAGE SHL 8) OR COWNERTAG_ATTR
; Page 3, Attribute=70h
call
dWriteOTString
; Write the string.
pop
bx
pop
dx
ret
; return to caller
dPaintOwnershipTag endp
****************************************************************************
DisplayOwnershipTag - This routine puts the Ownership tag on the normal (verbose) boot
screen.
Entry:
None
Exit:
String is displayed.
Regs:
flags.
Notes: This routine is called to display the normal string as well as the “clean boot” string.
-------------------------------------------------------------------------------------------------------------------
DisplayOwnershipTag proc near
push
dx
push
bx
mov
dh,OWNERTAG_ROW
; DH = Row to display string.
mov
bx,(NSCREEN_PAGE SHL 8)
+ OWNERTAG_ATTR
; Page 0, Attribute=07h
call
dWriteOTString
; Write the string.
pop
bx
pop
dx
ret
; return to caller
DisplayOwnershipTag endp
*****************************************************************************
dWriteOTString - This routine pumps the ownership tag out onto the screen.
Entry:
BL = Text attribute for string.
BH = Video page # to write to.
DH = Row to write string to.
Exit:
If user has set a string, it will be displayed.
Regs:
flags.
Notes: This routine is called to display the normal string as well as the “clean boot” string.
----------------------------------------------------------------------------------------------------------------
dWriteOTString proc near
push
es
push
ds
pusha
push
dx
;) Save entry parameters.
push
bx
;)
; Get Ownership Tag into DS:SI
; -------------------------------
mov
ax,0E845h
; AX=E845=”Get/Set NVS Features”
xor
bx, bx
; DL=0=”Read NVS Feature”
mox
cx, 13h
; CX=13=”Read Ownership Tag”
push
OT_SCRATCH_SEG
;)DS=Scratch segment
pop
ds
;)
mov
si.OT SCRATCH OFS
; SI = Scratch offset
int
15h
; Go get it!
jc
short pot_done
; If no ownership tag, get out.
; Determine length of ownership tag
; --------------------------------
push
ds
; )ES=DS
pop
es
;)
mov
di, si
; Go to end of string
mov
cx, 80
; Scan max 80 characters
add
di, cx
;) Start at end of string
dec
di
;)
std
; Scan backwards . . .
mov
al, ′ ′
; . . . for first non-space.
repe
scasb
; Do it!
jz
pot_done
; Y; ZF set=empty
inc
cx
; Adjust CX for last scasb
; DS,ES:SI=&OwnerTag, CX=Length
; Center and display string
; --------------------------------
mov
bp,si
; BP=Offset of string
pop
bx
; Restore page# and attribute
pop
dx
;) Restore row to show string
push
dx
;) Preserve stack integrity
push
bx
;]
mov
dl,80
; DL=# columns on screen
sub
dl, cl
;)
shr
dl, 1
;) DL = offset of centered string
mov
ax, 01300h
; AX-“Write String, keep cursor”
int
10h
; Write string!
pot_done:
pop
bx
;) Clean up stack
pop
dx
;}
popa
pop
ds
pop
es
ret
dWriteOTString endp
******************************************************************************
Read/Write the Ownership Tag. It is Administrator Password protected on writes. It resides in
the ESCD sector of the ROM.
NOTE: This is a code excerpt from a runtime service which is called by the ROM Setup Software
to read and/or write the Ownership tag. It demonstrates the password protected nature of
ownership tag, and shows how it is stored in a flash sector.
Ownership Tag:
mov
ex.OWNERSHIPTAG_LENGTH
;
call
outline_on?
; Q;ESCD from RUNTIME seg
jz
short ot runtime
; Y: Get it from runtime
; N: Get it from post buffer
push
es
; Save ES
mov
edi,ESCD_WRITE_BUFFER+OWNERSHIP_TAG AND 0FFFFh
pushw
((ESCD_WRITE_BUFFER+OWNERSHIP_TAG) SHR 4) AND 0F000h
jmp
short ot_common
; Join common code.
ot_runtime;
mov
edi,ESCD_RUNTIME_BUFFER+OWNERSHIP_TAG AND 0FFFFh
Setup ES for real/virtual/protected-16 bit calls that use read/write ESCD
setup_ES:
; Entry point to setup ES
push
es
; Save ES
mov
ax,cs
; Get CS
cmp
ax,0F000h
; Q: Real or Virtual 85 mode?
jne
ot_p16
; no must be protected-16
push
cs
jmp
short ot_common
; real mode just use cs
ot_p16;
; Protected-16 use ES they
push
es
; passed in. ES-base 0F000h
; limit 0FFFFh
ot_common;
pop
es
; ES = pointer to string data
Read/Write the Variables/Strings stored in the ESCD sector of the ROM.
Input:
ES:EDI
:= variable address in ESCD buffer
CS:EBP
:= CMOSFeaturess2 table entry address
ECX
:= string length
BL
:= Read/Write flag
DS:ESI
:= Read/Write buffer pointer
ReadWriteESCDStrs:
or
bl, b1
; Q: Reading?
jne
short WriteESCDStr
; N: go Write the ESCD String
; Y: return the ESCD String in DS:SI
test
cs:[ebp+FFLAG],PWPROT_RD
; Q: Is Read Password Protected?
je
short @f
; N: continue
; Y: check Admin PW
call
rwpd_test_admin_mode
stc
; assume falure
jz
short RWESCDStrsExit
; N. done
; Y: continue
@@:
mov
al, es: [edi]
;transfer the bytes
inc
edi
;
mov
[esi], al
;
inc
esi
;
loop
@b
; next byte
clc
; indicate success
jmp
short RWESCDStrs Exit
;
Transfer the new ESCD String to the ESCD buffer and then Flash the ROM via SMI.
WriteESCDStr:
test
ca; [ebp+FFLAG],PWPROT_WR
; Q: Is Write Password Protected?
je
short @f
; N: continue
; Y: check Admin PW
call
rpwd_test_admin_mode
stc
; assume falure
jz
short RWESCDStrsExit
; N: done
; Y: continue
@@:
call
hhwF000WriteEnable
; open up F0000h
@@:
mov
a1, [esi]
; transfer the bytes
inc
esi
;
mov
es;[edi], a1
;
inc
edi
;
loop
@b
; next byte
call
hhwF000WriteProtect
; close F0000h
call
UpdateFlashData_SMI
; go Flash the ESCD part of the ROM
clc
; indicate success
RWESCDStreExit:
pop
es
ret
********************************************************************************
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape, materials, components, circuit elements, wiring connections and contacts, as well as in the details of the illustrated circuitry and construction and method of operation may be made without departing from the spirit of the invention. | An “ownership tag” in a special area of memory of a computer system identifies an owner of the computer system by displaying the ownership tag during initialization of the computer system. The ownership tag may be presented during the installation and execution of the Basic Input Output System (BIOS) preferably during Power on Self Test (POST) process. An administrator may access the ownership tag by interrupting the process by pressing the an appropriate key, which transitions the computer to an administrator set up mode. An administrator able to enter the administrator password may then alter the contents of the protected memory, changing the ownership tag. The ownership tag is preferably stored in a region of memory not accessible to a typical user, but accessible to an administrator aware of the administrator password. The ownership tag is stored in a flash memory, which is very difficult to remove from the system board, or to modify without administrator-level security access. This makes it superior to conventional storage mechanisms such as RTC RPM, hard disk, etc. since these are easily modifiable and/or easily removable. | 6 |
RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 13/465,829, filed on May 7, 2012, which claims the benefit of U.S. Provisional Application Ser. No. 61/483,586 filed May 6, 2011, as well as U.S. Provisional Application Ser. No. 61/487,372 filed May 18, 2011, the contents of both of which are incorporated herein by reference in their entireties as if set forth in full.
BACKGROUND
1. Field of the Invention
The embodiments described herein relate generally to the field of radio-frequency identification (RFID) devices, and more particularly, to RFID switch tags.
2. Related Art
Conventional RFID tags lack the ability to be deactivated. However, there are certain situations where it is actually desirable to have an RFID tag deactivated. For example, in the context of traveling, RFID tags will often contain sensitive personal information stored within, for instance, an e-Passport, a visa, or a national identification card. Such information may contain the traveler's name, birth date, place of birth, nationality, and/or biometric information associated with that traveler. This information is intended to be read only by customs officials or other governmental authorities when the traveler enters or exits a country. However, since the read range of RFID tags can extend up to 30 feet, since an RFID tag does not need to be directly in the line of sight of an RFID reader, this sensitive information may be read by any number of unauthorized individuals as the individual walks through a train station or an airport. Unless the traveler houses his travel documents within a Faraday shield or other type of electro-resistant casing (which most travelers do not have), the sensitive information stored within the RFID tag remains perpetually at risk of being read by these unauthorized parties.
As a second example, consider RFID tags that are installed within automobiles, where such tags are used to facilitate automatic billing for the repeated use of certain toll-roads. In some of these toll-roads, the use of a car-pool lane is considered free of charge (which may be validly used, for example, when the automobile is housing at least one passenger other than the driver). Since a driver's RFID tag may not be deactivated, however, the RFID tag may respond to an interrogation signal issued from the toll-gate even when the driver has validly used the carpool lane. The result is that the driver may be billed for using the toll-road even when such use should have been considered free of charge because of the driver's valid use of the car-pool lane.
What is needed is a system for an RFID tag that may be easily activated or deactivated. Ideally, the system should be versatile and provide a clear sensory indication of the operational status of the RFID tag (i.e., activated or deactivated).
SUMMARY
Various embodiments of the present invention are directed to RFID switch devices. Such RFID switch devices advantageously enable manual activation/deactivation of the RF module. The RFID switch device may include a RF module with an integrated circuit adapted to ohmically connect to a substantially coplanar conductive trace pattern, as well as booster antenna for extending the operational range of the RFID device. The operational range of the RFID switch device may be extended when a region of the booster antenna overlaps a region of the conductive trace pattern on the RF module via inductive or capacitive coupling. In some embodiments, all or a portion of the booster antenna may at least partially shield the RF module when the RFID switch device is in an inactive state. The RFID switch device may further include a visual indicator displaying a first color if the RFID switch device is in an active state and/or a second color if the RFID switch device is in an inactive state.
In a first exemplary aspect, an RFID device is disclosed. In one embodiment, the RFID device comprises: a booster antenna adapted to extend the operational range of the RFID device; an RF module comprising an integrated circuit and a set of one or more conductive traces, wherein at least one conductive trace of said set of one or more conductive traces is adapted to electrically couple to a coupling region of the booster antenna when the coupling region of the booster antenna is located in a first position relative to said set of one or more conductive traces; and a switching mechanism adapted to change the position of the coupling region of the booster antenna relative to the position of said at least one conductive trace.
In a second exemplary aspect, an RFID transponder is disclosed. In one embodiment, the RFID transponder comprises: a first substrate comprising a first conductive trace pattern, wherein at least a portion of the first substrate is adapted to serve as an antenna for the RFID transponder; a second substrate comprising an integrated circuit and a second conductive trace pattern, wherein at least a portion of the second conductive trace pattern is adapted to electrically couple with at least a portion of the first conductive trace pattern when the first substrate is located in a first position relative to the second substrate; and a switching mechanism adapted to switch the position of the first substrate between a first position and at least a second position.
In a third exemplary aspect, an RFID device is disclosed. In one embodiment, the RFID device comprises: a booster antenna adapted to extend the operational range of the RFID device; a first RF module comprising a first integrated circuit and a first conductive trace pattern, wherein at least a portion of the first conductive trace pattern is adapted to electrically couple to a coupling region of the booster antenna when the coupling region of the booster antenna is located in a first position relative to the first conductive trace pattern; a second RF module comprising a second integrated circuit and a second conductive trace pattern, wherein at least a portion of the second conductive trace pattern is adapted to electrically couple to the coupling region of the booster antenna when the coupling region of the booster antenna is located in a second position relative to the second conductive trace pattern; and a switching mechanism adapted to change the position of the coupling region of the booster antenna relative to the positions of said first and second RF modules.
In a fourth exemplary aspect, an RFID device is disclosed. In one embodiment, the RFID device comprises: a first booster antenna adapted to extend the operational range of a first RF module; a second booster antenna adapted to extend the operational range of a second RF module; the first RF module comprising a first integrated circuit and a first conductive trace pattern, wherein at least a portion of the first conductive trace pattern is adapted to electrically couple to a coupling region of the first booster antenna when the coupling region of the first booster antenna is located in a first position relative to the first conductive trace pattern; a second RF module comprising a second integrated circuit and a second conductive trace pattern, wherein at least a portion of the second conductive trace pattern is adapted to electrically couple to the coupling region of the second booster antenna when the coupling region of the second booster antenna is located in a second position relative to the second conductive trace pattern; and a switching mechanism adapted to change the position of the coupling region of the first booster antenna relative to the first RF module, and the position of the coupling region of the second booster antenna relative to the second RF module.
In a fifth exemplary aspect, an RFID device is disclosed. In one embodiment, the RFID device comprises: a first booster antenna adapted to extend the operational range of an RF module as used with a first RFID service; a second booster antenna adapted to extend the operational range of the RF module as used with a second RFID service; the RF module comprising an integrated circuit and a conductive trace pattern, wherein at least a portion of the conductive trace pattern is adapted to electrically couple to a coupling region of the first booster antenna when the coupling region of the first booster antenna is located in a first position relative to the conductive trace pattern; and wherein at least a portion of the conductive trace pattern is adapted to electrically couple to a coupling region of the second booster antenna when the coupling region of the second booster antenna is located in a second position relative to the conductive trace pattern; and a switching mechanism adapted to change the position of the RF module relative to the respective coupling regions of the first and second booster antennas.
Other features and advantages of the present invention should become apparent from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments disclosed herein are described in detail with reference to the following figures. The drawings are provided for purposes of illustration only and merely depict typical or exemplary embodiments. These drawings are provided to facilitate the reader's understanding of the invention and shall not be considered limiting of the breadth, scope, or applicability of the embodiments. It should be noted that for clarity and ease of illustration these drawings are not necessarily made to scale.
FIG. 1 is a block diagram illustrating an exemplary RFID system according to one embodiment of the present invention.
FIG. 2A is a block diagram illustrating an exemplary RFID switch tag with its RF module located in a first position relative to its booster antenna according to one embodiment of the present invention.
FIG. 2B is a block diagram of the exemplary RFID switch tag with its RF module located in a second position relative to its booster antenna according to the embodiment depicted in FIG. 2A .
FIG. 2C is a block diagram of the RFID switch tag depicted in FIGS. 2A and 2B as depicted within an exemplary casing featuring a position-altering mechanism according to one embodiment of the present invention.
FIG. 3 is a block diagram illustrating an exemplary RFID switch tag including two RF modules and a single booster antenna according to one embodiment of the present invention.
FIG. 4 is a block diagram illustrating an exemplary RFID switch tag including two RF modules and two corresponding booster antennas according to one embodiment of the present invention.
FIG. 5 is a block diagram illustrating an exemplary RFID switch tag including a single RF module and two booster antennas that are tuned to different frequencies according to one embodiment of the present invention.
FIG. 6A is a front-side view of an exemplary switch-activated RFID tag according to one embodiment of the present invention.
FIG. 6B is a perspective view of the back side of the exemplary switch-activated RFID tag according to the embodiment depicted in FIG. 6A .
FIG. 7A is a back-side view of an exemplary circular-shaped and rotatable RFID switch tag in a first position according to one embodiment of the present invention.
FIG. 7B is a back-side view of the exemplary circular-shaped and rotatable RFID switch tag in a second position according to the embodiment depicted in FIG. 7A .
FIG. 7C is a front-side view of the exemplary circular-shaped and rotatable RFID switch tag depicted in FIGS. 7A and 7B .
FIG. 8A is a perspective view of the back side of an exemplary triangular-shaped and rotatable RFID switch tag in a first position according to one embodiment of the present invention.
FIG. 8B is a back-side view of the exemplary triangular-shaped and rotatable RFID switch tag in a second position according to the embodiment depicted in FIG. 8A .
FIG. 8C is a front-side of the exemplary triangular-shaped and rotatable RFID switch tag depicted in FIGS. 8A and 8B .
FIG. 9A is a perspective view of the back side of an exemplary switch-activated RFID tag according to one embodiment of the present invention.
FIG. 9B is a front-side view of the exemplary switch-activated RFID tag depicted in FIG. 9A .
FIG. 10 is a perspective view of an exemplary slide-activated RFID tag according to one embodiment of the present invention.
DETAILED DESCRIPTION
RFID is an automatic identification method, relying on storing and remotely retrieving data using devices called RFID tags or transponders. The technology relies on cooperation between an RFID reader and an RFID tag. RFID tags can be applied to or incorporated within a variety of products, packaging, and identification mechanisms for the purpose of identification and tracking using radio waves. For example, RFID is used in enterprise supply chain management to improve the efficiency of inventory tracking and management. Some tags can be read from several meters away and beyond the line of sight of the RFID reader.
Most RFID tags contain at least two parts: One is an integrated circuit for storing and processing information, for modulating and demodulating a radio-frequency (RF) signal, and for performing other specialized functions. The second is an antenna for receiving and transmitting the signal. As the name implies, RFID tags are often used to store an identifier that can be used to identify the item to which the tag is attached or incorporated. An RFID tag may also contain non-volatile memory for storing additional data as well. In some cases, the memory may be writable or electrically erasable programmable read-only memory (i.e., EEPROM).
Most RFID systems use a modulation technique known as backscatter to enable the tags to communicate with the reader or interrogator. In a backscatter system, the interrogator transmits a Radio Frequency (RF) carrier signal that is reflected by the RFID tag. In order to communicate data back to the interrogator, the tag alternately reflects the RF carrier signal in a pattern understood by the interrogator. In certain systems, the interrogator can include its own carrier generation circuitry to generate a signal that can be modulated with data to be transmitted to the interrogator.
RFID tags come in one of three types: passive, active, and semi passive. Passive RFID tags have no internal power supply. The minute electrical current induced in the antenna by the incoming RF signal from the interrogator provides just enough power for the, e.g., CMOS integrated circuit in the tag to power up and transmit a response. Most passive tags transmit a signal by backscattering the carrier wave from the reader. This means that the antenna has to be designed both to collect power from the incoming signal and also to transmit the outbound backscatter signal.
Passive tags have practical read distances ranging from about 10 cm (4 in.) (ISO 14443) up to a few meters (Electronic Product Code (EPC) and ISO 18000-6), depending on the chosen radio frequency and antenna design/size. The lack of an onboard power supply means that the device can be quite small. For example, commercially available products exist that can be embedded in a sticker, or under the skin in the case of low frequency RFID tags.
Unlike passive RFID tags, active RFID tags have their own internal power source, which is used to power the integrated circuits and to broadcast the response signal to the reader. Communications from active tags to readers is typically much more reliable, i.e., fewer errors, than from passive tags. Active tags, due to their on-board power supply, may also transmit at higher power levels than passive tags, allowing them to be more robust in “RF challenged” environments, such as high environments, humidity or with dampening targets (including humans/cattle, which contain mostly water), reflective targets from metal (shipping containers, vehicles), or at longer distances. In turn, active tags are generally bigger, caused by battery volume, and more expensive to manufacture, caused by battery price. Many active tags today have operational ranges of hundreds of meters, and a battery life of up to 10 years. Active tags can include larger memories than passive tags, and may include the ability to store additional information received from the reader, although this is also possible with passive tags.
Semi-passive tags are similar to active tags in that they have their own power source, but the battery only powers the microchip and does not power the broadcasting of a signal. The response is usually powered by means of backscattering the RF energy from the reader, where energy is reflected back to the reader as with passive tags. An additional application for the battery is to power data storage. The battery-assisted reception circuitry of semi-passive tags leads to greater sensitivity than passive tags, typically 100 times more. The enhanced sensitivity can be leveraged as increased range (by one magnitude) and/or as enhanced read reliability (by reducing bit error rate at least one magnitude).
FIG. 1 is a block diagram illustrating an exemplary RFID system according to one embodiment of the present invention. As shown by this figure, RFID interrogator 102 communicates with one or more RFID tags 110 . Data can be exchanged between interrogator 102 and RFID tag 110 via radio transmit signal 108 and radio receive signal 112 . RFID interrogator 102 may include RF transceiver 104 , which contains both transmitter and receiver electronics configured to respectively generate and receive radio transit signal 108 and radio receive signal 112 via antenna 106 . The exchange of data may be accomplished via electromagnetic or electrostatic coupling in the RF spectrum in combination with various modulation and encoding schemes.
RFID tag 110 can be a transponder attached to an object of interest and serve as an information storage mechanism. The RFID tag 110 may itself contain an RF module 120 (including an integrated circuit 122 and conductive trace pattern 124 ) as well as its own antenna 126 . All or a portion of the antenna 126 may be adapted to interact with the conductive trace pattern 124 in order to gather energy from the RF field to enable the device circuit 122 to function. In some embodiments, the antenna 126 used to gather the RF energy may be in a different plane as that of the integrated circuit 122 .
The data in the transmit signal 108 and receive signals 112 may be contained in one or more bits for the purpose of providing identification and other information relevant to the particular RFID tag application. When RFID tag 110 passes within the range of the radio frequency magnetic or electromagnetic field emitted by antenna 106 , RFID tag 110 is excited and transmits data back to RF interrogator 102 . A change in the impedance of RFID tag 110 can be used to signal the data to RF interrogator 102 via the receive signal 112 . The impedance change in RFID tag 110 can be caused by producing a short circuit across the tag's antenna connections (not shown) in bursts of very short duration. RF transceiver 104 can sense the impedance change as a change in the level of reflected or backscattered energy arriving at antenna 106 .
Digital electronics 114 (which in some embodiments comprises a microprocessor with RAM) performs decoding and reading of the receive signal 112 . Similarly, digital electronics 114 performs the coding of the transmit signal 108 . Thus, RF interrogator 102 facilitates the reading or writing of data to RFID tags, e.g. RFID tag 110 that are within range of the RF field emitted by antenna 104 . Together, RF transceiver 104 and digital electronics 114 comprise reader 118 . Finally, digital electronics 114 and can be interfaced with an integral display and/or provide a parallel or serial communications interface to a host computer or industrial controller, e.g. host computer 116 .
As stated above, conventional RFID devices lack the ability to be manually activated or deactivated. Various embodiments of the present invention are therefore directed to an RFID switch tag adapted to allow a user to manually change the operational state of the RFID device by activation of a lever, switch, knob, slider, rotating member, or other similar structure.
As shown generally by the embodiments depicted in FIGS. 2A-2C , a tag may provided that includes an RF module, strap, or interposer, as well as a booster antenna 210 . The RF module 220 may comprise an RFID integrated circuit in an ohmic connection to impedance matched conductive trace pattern in the same plane as the integrated circuit. Even though the RF module 220 is fully functional and testable, it may have a limited range of operation due to the small surface area of the conductive trace pattern.
According to one embodiment, the operational range of the RF module 220 can be increased by conductive or inductive coupling. For example, an impedance matched booster antenna 210 can be used in conjunction with the RF module 220 . In one embodiment, this booster antenna 210 consists of a conductive trace pattern on a substrate. In this example, there is no RF device on the booster antenna 210 . Rather, the RF module 220 and booster antenna 210 are provided with an area where they can overlap so that the capacitive or inductive coupling of energy occurs. The RF energy gathered from the booster antenna 210 may be transferred through the RF module substrate and conducted into the RF module 220 . This is illustrated in FIG. 2A . As shown, the RF module 220 may be positioned relative to the booster antenna 210 such that RF energy gathered via the booster antenna 210 is transferred to the RF module 220 .
While not shown, RF module 220 may comprise an RFID integrated circuit and a conductive trace pattern. These trace patterns can then be either inductively or capacitively coupled with a booster antenna 210 . For optimal performance, the booster antenna 210 may be matched with the RFID integrated circuit inputs. If RF module 220 is displaced or not sufficiently coupled with antenna 210 , then the operational range of the tag can be significantly reduced.
Thus, the placement of the RF module 220 with respect to the booster antenna 210 may alter the operational range and performance of the RFID tag 110 . This is illustrated in FIG. 2B . In FIG. 2B , the relative positions of the RF module 220 and the booster antenna 210 are different than the arrangement shown in FIG. 2A . In the arrangement of FIG. 2B , a smaller portion, or none, of the RF energy collected by the booster antenna 210 is transferred to the RF module 220 . In this manner, the effective operational range of the RFID tag 110 may be reduced as compared to the arrangement of FIG. 2A . In fact, because RF module 220 is completely or at least partially shielded by a portion of antenna 210 , RFID communications between the RFID tag 110 and the RFID reader interrogator 102 may be completely halted. This non-operational state may be useful, for instance, in situations where it is desirable to render the RFID tag 110 unresponsive to an RFID interrogation signal. For example, as noted above, when no toll is due on a toll road due to the number of passengers in the car, it may be desirable for the RFID tag 110 to be unresponsive to an RFID interrogation issued by a toll road portal system.
In some embodiments, a mechanism is provided for selectively altering the relative position of RF module 220 and the booster antenna 210 . Advantageously, this allows a user to selectively displace the RF module 220 from an optimized position over the booster antenna 210 rendering it unresponsive or detuned such that it will not respond at a sufficient measurement or perform adequately. Thus, for example, when taking a toll road that is free for car-pools, a user can manipulate the mechanism in order to effectively deactivate the RFID tag 110 and avoid paying the toll. In various embodiments, the mechanism may include a switch, lever, knob, slider, rotatable member, or any other device or construction which serves this purpose.
A selectively-activatable RFID tag 110 is depicted in FIG. 2C . The RFID tag 110 may comprise a slider mechanism 240 and an indicator area 250 , where the RF module 220 is mechanically coupled to the slider 240 . By manipulating the slider, a user modifies the relative positions of the RF module 220 and the booster antenna 210 . The indicator area 250 may provide a visual indication of the status of the RFID tag 110 . For example, if the RF module 220 and booster antenna 210 are positioned for effective transfer of RF power, the indicator area 250 may present a first visual indication such as a green color. Conversely, if the RF module 220 and booster antenna 210 are not positioned for effective transfer of RF power, the indicator area may provide a second visual indication such as a red color. In this manner, one or more individuals can be alerted of the effective operability of the RFID tag 110 .
FIG. 3 is a block diagram illustrating an exemplary RFID switch tag including two RF modules and a single booster antenna according to one embodiment of the present invention. As shown, a single booster antenna 310 is provided. However, in this embodiment two RF modules 322 and 324 are shown. The booster antenna 310 and RF modules 322 and 324 may be positioned such that only one of the two modules 322 and 324 is effectively coupled to the booster antenna 310 at any one time. For example, as shown in FIG. 3 , RF module 322 is coupled to the booster antenna 310 while RF module 324 is shielded. Thus, RF module 322 is effectively tuned and responsive, while RF module 324 is effectively detuned and unresponsive.
A mechanism (e.g., switch, slider, knob, lever, rotatable member, etc.) such as the slider 240 depicted in FIG. 2C may be provided for selectively altering the relative position of RF module 322 and 324 and the booster antenna 310 . In this manner, the positioning altering mechanism can be manipulated to selectively cause zero or one of the two modules 322 and 324 to be coupled to the antenna 310 . For example, in a first state, only module 322 may be coupled with the booster antenna 310 . In a second state, only module 324 may be coupled with booster antenna 310 . In a third state, neither modules 322 or 324 are coupled with the booster antenna 310 .
Advantageously, this arrangement allows a single RFID tag 110 to be used for multiple services. For example, one RF module, e.g. module 322 , can be associated with toll road portal system. The other RF module, e.g., module 324 , can be associated with a system for tracking car-pool lane use. The user can manipulate the position altering mechanism in order to couple the booster antenna 310 to the RF module 322 or 324 that is appropriate for current usage. In some embodiments, one or more visuals indicators may also be provided to indicate which RF module 322 or 324 is currently coupled to the booster antenna. Note also that while only two RF modules 322 and 324 are depicted in FIG. 3 , any number of RF modules may be used in accordance with embodiments of the present invention.
In the embodiment of FIG. 3 , the RF modules 322 and 324 may be aligned horizontally and the direction of movement caused by manipulation of the position altering mechanism may likewise be horizontal. In other embodiments, however, the RF modules 322 and 324 may be aligned vertically and the direction of movement may be vertical. In still other embodiments, the RF modules 322 , 324 may be arranged in an arcuate manner and the direction of motion may also be arcuate. Various other arrangements of the RF modules 322 and 324 , the booster antenna 310 , and the direction of movement are also possible according to embodiments of the present invention.
FIG. 4 is a block diagram illustrating an exemplary RFID switch tag including two RF modules and two corresponding booster antennas according to one embodiment of the present invention. As shown by the figure, two booster antennas 412 and 414 and two RF modules 422 and 424 are provided. In some embodiments, each RF module 422 and 424 may be associated with a different RFID service such that a user may independently tune each pair of RF modules 422 and 424 and booster antennas 412 and 414 present within the RFID tag 110 . Note that while only two pairs of RF modules 422 and 424 and booster antennas 412 and 414 are depicted in FIG. 4 , any number of RF module/booster antenna pairs may be utilized according to embodiments of the present invention.
While the embodiment depicted in FIG. 4 depicts the antennas 412 and 414 as bearing similar physical properties (such as size and shape), each booster antenna 412 and 414 may have differing physical properties according to alternative embodiments. These differences may result in different properties for gathering RF energies. In some embodiments, the antennas 412 and 414 may be specifically tuned to different frequencies.
According to some embodiments, each of the RF modules 422 and 424 may be attached to single position altering mechanism (not shown). In this manner, a user can manipulate the mechanism such that only one of the two RF modules 422 and 424 is coupled to its respective boost antenna 412 or 414 at any one time. A visual indicator may be provided to indicate which RF module 422 or 424 is currently coupled to its respective booster antenna 412 and 414 . In some embodiments, the position altering mechanism may be manipulated such that both or neither of the RF modules 422 or 424 are coupled to the respective boost antennas 412 or 414 at the same time.
In other embodiments, each of the RF modules 422 and 424 may be attached to a separate position altering mechanism (not shown). According to these embodiments, both, neither, or only one of the RF modules 422 or 424 may be coupled to the respective boost antennas 412 and 414 at the same time. The visual indicator may display a first color if the first RF module 422 is active and a second color if the second RF module 424 is active.
Note that in the embodiment depicted in FIG. 4 , the booster antennas 412 and 414 may be arranged along a vertical axis, and a horizontal direction of motion is utilized via manipulation of the position altering mechanism. However, persons skilled in the art will appreciate that the booster antennas 412 and 414 may be arranged horizontally, vertically, along an arc, in different planes, or in various other manners. Additionally, the direction of motion may switch the RF modules 422 and 424 between coupled and uncoupled positions for the respective booster antennas 412 and 414 .
FIG. 5 is a block diagram illustrating an exemplary RFID switch tag including a single RF module and two booster antennas that are tuned to different frequencies according to one embodiment of the present invention. As shown, a single RF module 520 may be provided, along with two booster antennas 512 and 514 . The booster antennas 512 and 514 may be configured with different physical properties to enable the RF module 520 to switch between separate RFID services. In this respect, the RF module 520 may be mechanically coupled to a position altering mechanism such that the tag can be switched to select one or none of the booster antennas 512 and 514 . A visual indicator may display a first color if the first booster antenna 512 corresponding to a first RFID service is selected and a second color if the second booster antenna 514 corresponding to a second RFID service is selected.
As in the case of FIG. 4 , the booster antennas 512 and 514 may be arranged along a vertical axis and the direction of motion of the RF module 520 caused by manipulation of the position altering mechanism is vertical. In other embodiments, the booster antennas 512 and 514 may be arranged horizontally, along an arc, in different planes, or in another manner and the direction of motion is adapted to switch the RF module 520 between the booster antennas 512 and 514 .
FIGS. 6A-10 generally depict various embodiments of RFID switch tags which may be utilized, for example, within an automobile setting. Each of the RFID switch tags may be affixed, fastened, or adhered to a windshield, rearview mirror, automobile exterior, or to various other areas of the automobile according to embodiments of the present invention.
FIG. 6A is a front-side view of an exemplary switch-activated RFID tag according to one embodiment of the present invention, while FIG. 6B is a perspective view of the back side of the exemplary switch-activated RFID tag according to the embodiment depicted in FIG. 6A . As shown by the figure, the RFID tag may include a slider configuration 602 with a window 604 on the outside and one or more icon graphics 606 on the opposite side. In some embodiments, an optional mounting component (not shown) may be used to adhere, fasten, or clip the RFID tag to a visor, for example.
FIG. 7A is a back-side view of an exemplary circular-shaped and rotatable RFID switch tag in a first position according to one embodiment of the present invention, FIG. 7B is a back-side view of the exemplary circular-shaped and rotatable RFID switch tag in a second position according to the embodiment depicted in FIG. 7A , while FIG. 7C is a front-side view of the exemplary circular-shaped and rotatable RFID switch tag depicted in FIGS. 7A and 7B . As depicted in FIGS. 7A and 7B , a circular shaped member 702 may be rotated, for example, clockwise or counterclockwise, in order to activate or deactivate the RFID switch tag. Icon graphics 706 on the back-side may be used to inform one or more individuals of the activation state of the RFID switch tag. Optionally, a window 704 on the opposite side of the RFID switch tag (see FIG. 7C ) may be used to reveal the activation state of the RFID switch tag to the outside.
FIG. 8A is a perspective view of the back side of an exemplary triangular-shaped and rotatable RFID switch tag in a first position according to one embodiment of the present invention, FIG. 8B is a back-side view of the exemplary triangular-shaped and rotatable RFID switch tag in a second position according to the embodiment depicted in FIG. 8A , while FIG. 8C is a front-side of the exemplary triangular-shaped and rotatable RFID switch tag depicted in FIGS. 8A and 8B . FIGS. 8A-8C may operate similar to FIG. 7A-7C , but utilize a substantially triangular shape and design rather than a circular one. Various other shapes and designs may also be utilized in accordance with embodiments of the present invention.
FIG. 9A is a perspective view of the back side of an exemplary switch-activated RFID tag according to one embodiment of the present invention, while FIG. 9B is a front-side view of the exemplary switch-activated RFID tag depicted in FIG. 9A . As depicted in FIG. 9A , the RFID tag may utilize a slider configuration 902 with a windows on both sides 904 and 905 of the RFID tag. Such an RFID tag may be adhered to the window of the automobile or may also use a cradle system for mobility according to various embodiments.
FIG. 10 is a perspective view of a separate exemplary slide-activated RFID tag according to one embodiment of the present invention. According to some embodiments, no physical switch or level is utilized. Instead, the RFID tag may be activated or deactivated by manually sliding a first substrate 1002 to or from a casing 1004 .
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not of limitation. The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments. Where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future. In addition, the invention is not restricted to the illustrated example architectures or configurations, but the desired features can be implemented using a variety of alternative architectures and configurations. As will become apparent to one of ordinary skill in the art after reading this document, the illustrated embodiments and their various alternatives can be implemented without confinement to the illustrated example. One of ordinary skill in the art would also understand how alternative functional, logical or physical partitioning and configurations could be utilized to implement the desired features of the present invention.
Furthermore, although items, elements or components of the invention may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. | Various embodiments of RFID switch devices are disclosed herein. Such RFID switch devices advantageously enable manual activation/deactivation of the RF module. The RFID switch device may include a RF module with an integrated circuit adapted to ohmically connect to a substantially coplanar conductive trace pattern, as well as booster antenna for extending the operational range of the RFID device. The operational range of the RFID switch device may be extended when a region of the booster antenna overlaps a region of the conductive trace pattern on the RF module via inductive or capacitive coupling. In some embodiments, all or a portion of the booster antenna may at least partially shield the RF module when the RFID switch device is in an inactive state. The RFID switch device may further include a visual indicator displaying a first color if the RFID switch device is in an active state and/or a second color if the RFID switch device is in an inactive state. | 6 |
RELATED APPLICATIONS
[0001] This application in part discloses and claims subject matter disclosed in my earlier filed patent application Ser. No. 12/386,825, filed on Apr. 23, 2009. This application also discloses and claims subject matter disclosed in my earlier filed patent application Ser. No. 12/380,928, filed on Mar. 4, 2009. These applications are incorporated by reference herein. Applicant claims priority under 35 USC §120 therefrom.
FIELD OF THE INVENTION
[0002] The present invention relates to tongue and groove floor, ceiling and wall panels sculpted out of a single piece of wood or other material, with a veneer atop each panel.
BACKGROUND OF THE INVENTION
[0003] Floor panels, such as parquet floor panels, are typically made of an array of interlocking tongue and groove panels. However, often the grooves are gouged out of a single piece of wood, and the corresponding tongues are sculpted out of a single piece of wood, making their manufacture time consuming and subject to minute, small errors.
[0004] U.S. Pat. No. 2,257,048 of Fulbright describes a panel with multiple layers glued together.
[0005] The flooring of Martensson in his U.S. Pat. No. 6,101,778, uses a solid base layer with bonded profiled edges providing snap-together profiles. U.S. Pat. No. 2,283,135 of Bruce for flooring uses solid strips of wood with no veneer upper layer. The flooring of Martensson in his U.S. Pat. No. 6,101,778, uses a solid base layer with bonded profiled edges providing snap-together profiles. However, Martensson '778 requires coupling the respective tongue 7 and groove 6 to respective separate panels 1 , each respective panel 1 having respective lower portions 15 which mate with corresponding flanges 16 and 14 extending respectively from tongue 7 and groove 6 .
[0006] U.S. Pat. No. 2,283,135 of Bruce for flooring uses solid strips of wood with no veneer upper layer. Bruce 135 also uses nails 10 to attach elongated strips 1 to subflooring, a feature not required by Applicant's interlocking panels.
[0007] Martensson '778 therefore uses the idea of one side clamping to the other side, Martensson '778 also uses long panels, not interlocking square panels like the Applicant herein. Martensson '778 does not describe a system where oppositely located, coordinated rotating bits can sculpt not only the tongue and grooves of wall panels from solid blocks, and Martensson cannot sculpt panel edges by rounding or texturing them. Martensson does not describe using coordinated pairs of rotating bits that changes the surface topography of wall panels to the designer's liking and preferences. Martensson '778 does not describe a method of simultaneously cutting opposing sides of a floor panel at the same time, which would make the panels more uniform in structure.
OBJECTS OF THE INVENTION
[0008] It is therefore an object of the present invention to provide tongue and groove floor, ceiling and wall panels using multiple bonded sheet construction, with minimal or no gouging or sculpting of pieces of wood.
[0009] It is also an object to provide a panel made up of three sheets of substantially the same equal thickness, and to form respective protruding tongues and receptacle grooves from overlapping of the substantially equal thick sheets forming the panel.
[0010] It is also an object of the present invention to provide a relatively tight fit of the tongue portions into the respective groove portions of the assembled sheets forming each panel.
[0011] It is also an object of the present invention to be able to install multiple floor, ceiling or wall board panels in a single plane parallel to the surface upon which the panels are being installed.
[0012] Other objects which become apparent from the following description of the present invention.
SUMMARY OF THE INVENTION
[0013] In keeping with these objects and others which may become apparent, the floor, ceiling and wall panels of this invention are constructed of multiple board sheets, preferably three board sheets, of material bonded together using adhesive. The preferred material for each of the board sheets is plywood which may be of different or the same thickness for each. Other rigid durable sheet materials may be used such as flake board or composites incorporating wood materials. Materials such as foamed PVC can also be used for one or all three of the layers. The three pieces of plywood can be attached not only by adhesive, such as glue, but also by fasteners, such as nails, staples, etc. joining one or more of the three layers. The three pieces of plywood also can have plastic sheets inserted between the panels to reduce moisture between them. Also, the three layers can use different types of plywood. Optionally, each plywood board sheet layer can be treated differently to be water resistant, fire proof or insect resistant, etc. A typical fire resistant wood sealer such as described in U.S. Pat. No. 5,879,593 is mixed with the glue before the glue is applied between the layers. Optionally, waterproof glues, such as Gorilla® glue or Titebond® waterproof glue may be used. Fireproof glue, such as GB18583-2001/BS5852 manufactured by Stenzhen Gokangali Chemical Laboratory, Ltd. may be used and mixed with the glue. Insect resistant adhesives, such as manufactured by Henkel Adhesives can also be mixed with the glue and applied between the board layers.
[0014] In one embodiment for floor boards, all three board sheets are of identical size and shape (although the thickness may be different as desired). The shape, as described in the drawings, is either square or rectangular. (Other tiling shapes, such as hexagons or octagons, with straight sides may also be used.) By offsetting the middle board sheet layer so that two adjacent sides extend beyond the top and bottom board sheet layers which are in registration, a protruding tongue is developed on two adjacent sides while the opposite sides will have grooves. Thus such panels can be used to cover a large floor, ceiling or wall area using normal tongue-in-groove techniques by fitting the protruding tongues into the grooves of adjacent panels; a small amount of adhesive may be used in these fitted edges, but it is not essential in all applications. No routing of the edges is required to form the tongues or grooves.
[0015] In an alternate embodiment for walls and ceilings, the middle board sheet is smaller in size than the top and bottom board sheets which are in registration. The middle board sheet is centered within the top and bottom board sheets thus forming grooves on all four edges. To assemble these panels to cover a larger area, separate connecting slat tongues are used to connect the panels thereby acting as the tongues for a tongue-in-groove fit. By using a combination of short slat tongues and long slat tongues, large interconnected areas can be covered. By using slat tongues wider than the depth of two adjacent panel grooves, visible linear grooves the depth of the thickness of the top board sheet are formed between panels. They can be used to simulate a grout line in ceramic tile installations.
[0016] The top surface of each panel can be finished in a variety, of ways including grooving to simulate a parquet floor or patterns formed of veneers with oriented grain directions. It is also known that the pattern can be enhanced by one or more veneer pieces applied to the top of the assembled panels. Any appropriate sealant and/or stain can be used. Obviously the finish for a floor application would probably be different from that of a wall panel due to wear characteristics. Large inlay designs can be accommodated on several adjacent panels which are then assembled like a jigsaw puzzle to form a coherent design.
[0017] The tongue and the reciprocating groove are formed by attaching three panel board sheets, preferably plywood, together in a “sandwiched” overlying pattern. Because the plywood board sheets are flat, the tongues and corresponding grooves extend uni-directionally therefrom. They can be assembled by moving the tongue portions in one surface plane, such as horizontally for a floor or ceiling, and vertically for a wall. They do not need to be inserted at an angle and then locked in place by being moved in a non-planar fashion.
[0018] It is further noted that in the case the underlying wall to which the panels are being installed is warped and non-planar, an underlying layer of Sheetrock® wall board can be installed between the panels and underlying warped surface, to provide a relatively flat surface for installation of the array of panels.
[0019] In an alternate embodiment, the square or rectangular floor, wall, or ceiling panels are of different construction using a different fabrication method. The three-layer plus veneer construction of the embodiment above is replaced by a single solid layer with a veneer layer on top. The single layer is preferably a wood product such as plywood, high density fiberboard (HDF), or medium density fiberboard (MDF). The fabrication method involves the use of edge routing using a tongue cutter on one edge and a groove cutter on the opposite edge to form the edge shapes equivalent to those of the previous embodiment. If two routing heads are spaced apart the appropriate distance for a particular sized panel, a single pass can form a tongue on one edge and a groove on the opposite edge simultaneously. One cutter is spun clockwise while the second is spun counterclockwise to equalize the forces on the panel. Thus two passes are needed to form the edges of a panel. If the panel is square, the spacing of the two router heads need not be changed to form the edges orthogonal to the first ones formed. The veneer layer, which may be bamboo, birch, or other woods such as cherry wood, is adhesively bonded to the top surface as in the earlier embodiment.
[0020] It is further noted that the wood material can be as described in my co-pending patent application Ser. No. 12/380,928 filed Mar. 4, 2009. In that application, I describe a wood article of manufacture thus produced which can be a laminate panel of particle board of particular particle size and particle to glue ratios which provides a durable, lightweight and strong panel which gives the appearance of wood because its exterior veneer layer or layers are made from a thin wood veneer of approximately 0.35 to 0.70 millimeters in thickness. A preferable veneer thickness is 0.5 mm, although veneer thicknesses may range from 0.3 to 0.5 mm, although other suitable thicknesses may be used.
[0021] My co-pending application Ser. No. 12/380,928 describes that to keep the wood lightweight, the particles should be more than 1.0 mm and less than 5.0 mm in length, depth and width, preferably about 3.0 mm in length, depth and width so that they are small enough to have sufficient density for strength, but large enough to provide air spaces therebetween, to be filled by resin glue at a weight lighter than natural wood. The ratio of wood particles to glue should be preferably 100:10 to 100:12, i.e. 100 kg of raw wood particle material to mix with 10-12 kg of glue. The maximum permitted is 100:28, i.e. 100 kg wood particle to 28 gms glue. With the aforementioned parameters, the finished particle board density is 0.8 g/cm 3 . To keep the panels smooth and flat, sanding should be applied to keep height deviation within 0.1 mm. Also, to have sufficient glue without undue buildup or air bubbles, glue should be applied in the ratio of 320 g/m 2 . To further keep the panels smooth, the thin veneer layers with glue are heat and pressure treated at 110 C and pressure of about 1 cm 2 per 7-8 kg. On the edges, veneer strips of about 1.5 cm in with and 0.5 to about 1 mm in thickness, with lengths of 1 meter or more, are applied at a pressure of approximately 200 pounds with a glue at approximately 200 degrees C. heat. For fireproofing, insect proofing or water proofing, a thin layer of Wood Fire Resisting Liquid is applied by putting the panels in a tank full of liquid of pressure more than 1, 2 Mp 3 P for at least 8 hours immersion, which will soak about 150 kg/cubic meter of product into the wood. At low ambient pressure, the wood must be soaked for at least 48 hours, as long as 80 to 100 kg/cubic meter is absorbed into the wood over the 48 hour period. Exterior brushing can also be applied in three layer coatings to a thickness of 0.5 kg/cubic meter. Although other fire resistant, water resistant and pest or mold resistant sealers can be applied, a typical fire resistant liquid wood sealer is described, for example, in U.S. Pat. No. 5,879,593, including a liquid composition of potassium hydroxide, sodium carbonate, silica and water.
[0022] My co-pending application Ser. No. 12/380,928 also describes a manufacturing system, method, and article of manufacture which is capable of producing a laminated product that has the appearance of traditional birch plywood. The laminated article of manufacture has an interior similar to that of particle board, but the laminated article of manufacture should has increased strength and lighter weight compared to that of other particle boards. Additionally, the laminated article of manufacture is capable of having at least one or a plurality of thin or ultra-thin veneers placed on opposing surfaces and opposing edges, and is capable of being painted. The laminated article of manufacture is capable of being manufactured from recycled biodegradable products. In the U.S. and Europe, the natural color of a natural wood surface having a clear coat with the texture of the wood showing through is highly desirable, especially that of Birch Wood grown in Northern Asia, (Northern China and Russia). Birch wood also has characteristics of surface hardness, beautiful texture, a minimum amount of scar marks, black lines, or mineral lines, does not easily break or change shape after having been cut in the format of veneer sheet (usually in the size of 4 feet by 8 feet, 0.3 mm to 0.5 mm in thickness), but these high quality veneers are becoming less and less available, because a 3 foot or larger diameter birch tree takes more than 60 years to grow, and there are only 3 to 5 sheets of 4 feet by 8 feet veneers in that tree. These 3 to 5 sheets of veneers, may be used on surfaces of 4 feet by 8 feet plywood, and used for the manufacture of 5 storage units for toys. One class room of furniture, however, needs at least 5 times of this amount of veneer, which means that a classroom's furniture needs five birch trees to manufacture the furniture.
[0023] My co-pending application Ser. No. 12/380,928 further describes a system which may be used instead of using birch veneer. Chinese Cottonwood (called Chinese Birch or Chinese beech) which grows on tree farms and takes approximately 7-10 years to grow, and which grows into a one and half foot diameter tree may be used. Veneers from these trees, however, have soft surfaces that may scratch easily. However, such veneers may be hardened by methods of the present invention, resulting in finished products that look substantially the same as Russian Birch, or other highly desired woods.
[0024] My co-pending application Ser. No. 12/380,928 also describes that by using the above wood materials and paint processes of the present invention, wood products can be made completely of recycled wood and veneers from fast growing Chinese trees, thus, minimizing impact to the environment.
[0025] My co-pending application Ser. No. 12/380,928 further describes a core of fresh or green wood and/or recycled wood products, which are processed down to a particle size of less than 5 mm, and preferably less than 3 mm, and bonded together with glue, opposing surface inner veneer bonded to opposing surfaces of the core with glue, opposing surface outer veneer bonded to opposing surface inner veneer with glue, opposing edge veneer bonded to opposing edges of the core with glue. Each of the veneers is preferably 0.5 mm thick, although suitable veneer thicknesses may range from 0.3 to 0.5 mm. The article of manufacture thus produced is a laminated wood product having a particle to glue ratios that provides a durable, lightweight, strong attractive product that gives the appearance of wood.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The present invention can best be understood in connection with the accompanying drawings. It is noted that the invention is not limited to the precise embodiments shown in drawings, in which:
[0027] FIG. 1 is a perspective exploded view of three board sheets forming a square panel with integral tongues on two edges and grooves on the other two.
[0028] FIG. 2 is a top view of the assembled panel of FIG. 1 .
[0029] FIG. 3 is a top view of an alternate embodiment square panel with grooves on all four edges.
[0030] FIGS. 4A to 4F show a typical installation of the floor board panels, wherein:
[0031] FIG. 4A is a top plan view of a floor panel;
[0032] FIG. 4B is a front elevation view thereof;
[0033] FIG. 4 BB is a close up partial detail view of the floor panel in FIG. 4B , taken along view circle line “ 4 BB” of FIG. 4B ;
[0034] FIG. 4C is a right side elevation view thereof;
[0035] FIG. 4D is a close detail view taken along view circle line 5 D of FIG. 5C ;
[0036] FIG. 4E is a top plan view during installation of an array of multiple panels; and
[0037] FIG. 4F is a top plan view after completion of installation of the array of multiple panels.
[0038] FIGS. 5A to 5R show the installation of a typical wall board, wherein:
[0039] FIG. 5A is a top plan view of a wall panel 10 of square configuration as in FIG. 3 ;
[0040] FIG. 5B is a front elevation view thereof;
[0041] FIG. 5C is a right side elevation view thereof;
[0042] FIG. 5D is a close up detail view taken along view circle line “ 5 D” of FIG. 5C ;
[0043] FIG. 5E is top plan view of a connecting slat for the panel of FIG. 16A ;
[0044] FIG. 5F is front view thereof.
[0045] FIG. 5G is side view thereof;
[0046] FIG. 5 GG is a close-up detail view of the connecting slat shown in FIG. 5G , taken along view circle line “GG” of FIG. 5G ;
[0047] FIG. 5H is a top plan view of a rectangular wall panel;
[0048] FIG. 5I is a right side elevation view thereof;
[0049] FIG. 5J is a front elevation view thereof;
[0050] FIG. 5K is top plan view of a connecting slat for the panel of FIG. 16H ;
[0051] FIG. 5L is front view thereof;
[0052] FIG. 5M is a top plan view of an array of wall panels during installation;
[0053] FIG. 5N is a top plan view of the array of wall panels also showing connecting slats;
[0054] FIG. 5O is a top plan view of a completed array of wall panels;
[0055] FIG. 5P is a top plan view of the array of connecting slat tongues for the wall panels;
[0056] FIG. 5Q is inverted cross sectional view viewed through view line “ 5 Q- 5 Q” of FIG. 50 ;
[0057] FIG. 5R is a close-up detail view of taken along viewing circle line “ 5 R” of FIG. 5Q ;
[0058] FIGS. 6A-6R show the installation of a typical ceiling pattern, wherein:
[0059] FIG. 6A is a top plan view of a ceiling panel 100 of square configuration, similar to wall panel 10 as in FIG. 3 ;
[0060] FIG. 6B is a front elevation view thereof;
[0061] FIG. 6C is a right side elevation view thereof;
[0062] FIG. 6D is a close up detail view taken along view circle line “ 6 D” of FIG. 6C ;
[0063] FIG. 6E is top plan view of a short connecting slat for the panel of FIG. 6A ;
[0064] FIG. 6F is front view thereof.
[0065] FIG. 6G is side view thereof;
[0066] FIG. 6H is a close up partial detail thereof, taken along view line circle “ 6 H” of FIG. 6G ;
[0067] FIG. 6I is a top plan view of a long rectangular slat for the ceiling panel;
[0068] FIG. 6J is a front view thereof;
[0069] FIG. 6K is a right side elevation view thereof;
[0070] FIG. “ 6 L” is a close up detail thereof, taken along view line circle “ 6 L” of FIG. 6K ;
[0071] FIG. 6M is a top plan view of an array of ceiling panels and connecting slats during installation;
[0072] FIG. 6N is a top plan view of the array of ceiling panels further during installation;
[0073] FIG. 6O is a top plan view of the array of connecting slat tongues for the ceiling panels;
[0074] FIG. 6P is a top plan view of a section of panels installed on a ceiling;
[0075] FIG. 6Q is an inverted cross sectional view viewed through view line “ 6 Q- 6 Q” of FIG. 6P ;
[0076] FIG. 6R is a close-up detail view taken along view circle line “ 6 R” of FIG. 6Q ;
[0077] FIG. 7 is a top view of an alternate embodiment showing a square panel fabricated using a different method, wherein the base section is a single solid layer with a veneer layer bonded on top;
[0078] FIG. 8 is an edge view of the panel of FIG. 7 ;
[0079] FIG. 9 illustrates the fabrication method using two counter-rotating routing heads;
[0080] FIG. 9A is an enlarged close-up detail view of a modified bit with a textured cutting edge;
[0081] FIG. 9B is an enlarged close-up detail view of a modified panel tongue with surface texturization imparted by a bit with a textured cutting edge; and,
[0082] FIG. 9C is an enlarged close-up detail view of a of a modified panel groove with surface texturization imparted by a modified bit with a textured cutting edge.
DETAILED DESCRIPTION OF THE INVENTION
[0083] FIG. 1 shows three equal-sized board sheet layers, top 2 , middle 3 , and bottom 4 which will be adhesively bonded at the factory to form square panel 1 of the first embodiment with an offset middle layer. Each of the layers is preferably a board sheet of plywood. They can all be the same thickness, such as 6 mm, or the board sheets can be of different thickness as desired. These panels, of convenient size such as 12″ or 16″ can be used as floor tiles or for wall covering. While dimensions may vary, preferably square panels 1 have upper board sheets 2 and lower board sheets 4 which are 32 cm in length, sandwiching a mid board sheet 3 of 32 cm in length, which extends outward displaying a protruding tongue of 1.3 cm and a corresponding recess on an opposite side of 1.3 cm in depth. Each board sheet is preferably 6 mm, making panel 1 of three board sheets 2 , 3 and 4 about 18 mm in thickness.
[0084] Each board sheet is preferably a rectangular cuboid, also called a rectangular parallelepiped, of which all faces are rectangular and where “rectangular” implies both rectangles and squares.
[0085] Each of the panels may be of one piece construction, plywood, or other suitable construction. A preferred embodiment of a floor panel system, as in FIG. 1 and FIGS. 4A-4F , constructed in accordance with the present invention comprises:
[0000] A floor panel system, comprising:
a plurality of substantially same size and shape wood floor panels 1 matingly and releasably adjoined one to the other, each floor panel 1 of the plurality of substantially same size and shape wood floor panels 1 adapted to matingly and releasably adjoin to at least two other floor panels 1 of the plurality of substantially same size and shape wood floor panels 1 ,
the each floor panel 1 having:
opposing substantially rectangular cuboid shaped one piece wood board sheets 2 and 4 ,
each opposing substantially rectangular cuboid shaped one piece wood board sheets 2 and 4 of the opposing substantially rectangular cuboid shaped one piece wood board sheets 2 and 4 comprising: substantially flat opposing first and second surfaces, opposing first edges substantially perpendicular to the substantially flat opposing first and second surfaces, opposing second edges substantially perpendicular to the substantially flat opposing first and second surfaces and substantially perpendicular to the substantially opposing first edges,
a substantially centrally disposed substantially rectangular cuboid shaped one piece wood board sheet 3 having substantially the same size and shape as the each opposing substantially rectangular cuboid shaped one piece wood board sheet and having substantially flat opposing third surfaces, opposing third edges, and opposing fourth edges,
the substantially flat opposing third surfaces bonded to each the substantially flat opposing second surface of the each opposing substantially rectangular cuboid shaped one piece wood board sheet and configured to have one of the opposing third edges and one of the opposing fourth edges extending from the each floor panel 1 forming substantially perpendicular adjacent tongues and substantially perpendicular adjacent grooves.
[0096] FIG. 2 shows a top view showing how the offset center board sheet 3 simultaneously forms two adjacent tongue edges as well as two opposite groove edges 5 .
[0097] FIG. 3 is a top view of square panel 10 with smaller central board sheet 13 , top board sheet 11 , bottom board sheet 14 and grooves 12 on all four edges. External tongue slats are used with this embodiment.
[0098] Each of the panels may be of one piece construction, plywood, or other suitable construction. Each board sheet is preferably a rectangular cuboid, also called a rectangular parallelepiped, of which all faces are rectangular and where “rectangular” implies both rectangles and squares.
[0099] A preferred embodiment of a wall panel system, as in FIGS. 5A-5R constructed in accordance with the present invention, or a ceiling panel system, as in FIGS. 6A-6R , comprises:
[0000] a wall or ceiling panel system, comprising:
a plurality of substantially same size and shape wood wall or ceiling panels 10 or 100 panels 100 matingly and releasably adjoined one to the other, each wall or ceiling panel 10 or 100 of the plurality of substantially same size and shape wood wall or ceiling panels 10 or 100 adapted to matingly and releasably adjoin to at least two other wall or ceiling panels 10 or 100 of the plurality of substantially same size and shape wood wall panels 10 or ceiling panels 100 ,
the each wall panel 10 or ceiling panel 100 having:
opposing substantially rectangular cuboid shaped one piece wood board sheets 11 and 14 ,
each opposing substantially rectangular cuboid shaped one piece wood board sheet 11 and 14 of the opposing substantially rectangular cuboid shaped one piece wood board sheets 11 and 14 comprising: substantially flat opposing first and second surfaces, opposing first edges substantially perpendicular to the substantially flat opposing first and second surfaces, opposing second edges substantially perpendicular to the substantially flat opposing first and second surfaces and substantially perpendicular to the substantially opposing first edges,
a substantially centrally disposed substantially rectangular cuboid shaped one piece wood board sheet 13 smaller than and having substantially the same shape as the each opposing substantially rectangular cuboid shaped one piece wood board sheets 11 and 14 and having substantially flat opposing third surfaces, opposing third edges, and opposing fourth edges,
the substantially flat opposing third surfaces bonded to each the substantially flat opposing second surface of the each opposing substantially rectangular cuboid shaped one piece wood board sheet and sandwiched therebetween and configured to have the opposing third edges and the opposing fourth edges inwardly disposed within the each wall panel 10 forming opposing first grooves 12 and opposing second grooves 12 substantially perpendicular to the opposing first grooves, each the opposing first groove 12 of the opposing first grooves 12 and each the opposing second groove 12 of the opposing second grooves 12 having substantially the same depth;
a plurality of spacer block standoffs 27 adapted to be fastened to a wall or ceiling; a plurality of first connecting slat tongues fastened to the plurality of standoffs 27 ,
each first connecting slat tongue of the plurality of first connecting slat tongues adapted to be matingly and removably received within two adjacent abutting opposing first grooves of the opposing first grooves of two adjacent abutting the plurality of substantially same size and shape wood wall panels 10 or ceiling panels 100 ;
a plurality of second connecting slat tongues 28 ,
each second connecting slat tongue 28 of the plurality of second connecting slat tongues 28 adapted to be matingly and removably received within two adjacent substantially collinear second grooves 12 of the opposing second grooves 12 of the two adjacent abutting the plurality of substantially same size and shape wood wall panels 10 or ceiling panels 100 and substantially perpendicular to the plurality of first connecting slat tongues 26 .
[0115] FIGS. 4A-4F show a typical installation of the array of floor board panels 1 with equal sized floor board panels 1 made of top panel board sheet 2 , staggered mid panel board sheet 3 leaving two adjacent tongue portions and lower panel board sheet 4 , wherein the staggered tongues engage grooves 5 forward between opposite edges of top panel board sheet 2 and lower panel board sheet 4 of an adjacent wall panel 10 . While dimensions may vary, preferably square panels 1 have upper board sheets 2 and lower board sheets 4 which are 32 cm in length, sandwiching a mid sheet 3 of 32 cm in length, which extends outward displaying a protruding tongue of 1.3 cm and a corresponding recess on an opposite side of 1.3 cm in depth. Each board sheet is preferably 6 mm, making panel 1 of three board sheets 2 , 3 and 4 about 18 mm in thickness. Floor board panels 1 are installed in a plane in the direction of the arrows indicated.
[0116] FIGS. 5A-5R show the installation of a typical wall board, where the panels are joined by short slat tongues 26 or long slat tongues 28 of FIG. 11 , which are fastened by fasteners such as nails or screws through slats 26 or 28 and through standoff spacer blocks 27 to an underlying wall surface.
[0117] Each top and bottom board sheets 11 and 14 of square panel 10 of FIGS. 3 and 5A , is preferably 39 cm square, sandwiching smaller mid board sheet 13 of 37 cm in length therebetween. Connecting slat tongues 26 are preferably 37 cm in length and 3.6 cm in width and 0.7 cm in thickness, to fit in the grooves 12 on all sides of panel 10 , wherein grooves 12 are 0.7 cm in width, to engage corresponding tongues of 0.7 cm in length.
[0118] Each top and bottom board sheets of rectangular panels 10 a of FIG. 5H are also 39 cm in width, but 120.2 cm in length. Smaller mid board sheets are 3.6 cm in width and 199.4 cm in length, engaging corresponding grooves of 199.4 cm in length formed within rectangular panels 10 a.
[0119] As shown in FIG. 50 , when assembled in the vertical planar direction of the arrows, two square panels plus corresponding slat tongues each have a length of 40.6 cm×40.6 cm, combined with a long rectangle and corresponding slat tongue totaling 121.8 cm in length, for a combined assembly of 203 cm. Other panels may be added depending upon the wall size to be covered.
[0120] In an alternate embodiment, the wall panels can be installed on a ceiling, but preferably each square panel is 2 feet by 2 feet (60.96 cm×60.96 cm).
[0121] FIG. 6A is a top view of square ceiling panel 100 with smaller central board sheet 113 , top board sheet 111 , bottom board sheet 114 and grooves 112 on all four edges. External short connecting slat tongues 126 and long connecting slat tongue 128 of FIG. 6E through 6L are used with this embodiment to connect ceiling panels 100 to each other. Slat tongues 126 or 128 are inserted in place in a plane, in the direction of the arrows shown in FIG. 6M and FIG. 6N . The ceiling panels 100 are connected to a ceiling in a manner similar to that of wall panels in FIG. 5A through FIG. 5R , with fasteners, such as nails or screws, through slat tongues 126 or 128 and bracing standoff spacer blocks 127 . While dimensions may vary, ceiling panels 100 are preferably 60.8 cm square (approximately two feet square). Mid panel board sheet 113 is about 56.8 cm square, revealing grooves on all four sides of about 2 cm in depth. Top board sheet 11 is about 0.4 cm in thickness, mid board sheet 113 is about 0.6 cm (as is groove 112 formed thereat) and bottom board sheet is about 0.5 cm in thickness. Short slat tongues 126 are about 5.8 cm×6.54 cm, and long slat tongues 128 are about 120.14 cm in length×6.54 corn in width. FIG. 6Q shows a section of a ceiling covered by a number of square ceiling panels 100 . Ceiling board panels 1 are installed in a plane in the horizontal planar direction of the arrows indicated. The ceiling panels 100 can be also installed suspended in a drop ceiling configuration, where there are perpendicular connectors or frames spaced between the panels 100 and the ceiling surface above the panels.
[0122] In an alternate embodiment for floor panel 1 , as previously shown in FIGS. 1 , 2 , and 4 A- 4 F, while the three board sheets are substantially equal in thickness, in this alternate embodiment mid board sheets 3 forming tongues may be alternatively slightly thicker at the tongue end than at the end forming the groove between respective top and bottom board sheets 2 and 4 , so that they form a tight fit when pushed into the respective grooves formed between top board sheet 2 and bottom board sheet. For example, the protruding end can be 0.63 cm but the groove can be 0.6 cm. Floor board panels 1 are installed in a plane in the direction of the arrows indicated, without any need to divert away from the horizontal planar direction of installation.
[0123] FIGS. 7-9 pertain to an alternate embodiment of panel of this invention which can be used for the same purposes as in FIGS. 4A-4F , 5 A- 5 R, and 6 A- 6 R. Although the panel is shown as a square panel, the fabrication method can also be extended to cover any rectangular panel as well.
[0124] FIG. 7 shows panel 200 with top veneer layer 202 which is adhesively bonded and protruding tongue edges 204 . FIG. 8 is a side edge elevation of panel 200 showing solid base layer 210 and tongue 204 on one side with matching groove 206 on the opposite edge. Note that panel 200 has the same geometric edge features and veneer placement as the panel described if FIGS. 1-3 . Base layer 210 is typically plywood, HDF, or MDF.
[0125] FIG. 9 illustrates the fabrication method whereby two opposite edges are formed simultaneously. Panel 200 is fed between two counter-rotating routing cutters, 215 and 217 cutting the tongue and groove respectively on opposite edges. The spacing of cutters 215 and 217 matches the desired panel dimensions.
[0126] Each panel can vary in size, but is preferably 30 cm by 30 cm in length and width. The solid supporting layer is preferably 2 cm in height and the top veneer is preferably 0.6 cm in height, although it can be varied up to preferably 0.8 or 1.0 cm in height. Preferably the total panel height is between about 2.6 cm to 3.0 cm in height. The tongue portion protrudes out about 1.5 cm in two directions and the respective grooves are each about 1.5 cm in depth.
[0127] FIGS. 9A , 9 B and 9 C show an alternate embodiment for a method of imparting extrications, such as serrations, threaded cuts and other textures surfaces, which can be used to provide a stronger gripping surface between the tongue of a panel with the groove of an adjacent panel.
[0128] For example, FIG. 9A shows a modified bit 315 with a textured cutting edge 316 .
[0129] FIG. 9B shows a modified panel 300 with a tongue 304 having surface texturization 305 imparted by a bit 315 with a textured cutting edge 316 .
[0130] FIG. 9C shows a modified panel 300 ′ with a groove 306 having surface texturization 307 imparted by a modified bit with a textured cutting edge.
[0131] In the foregoing description, certain terms and visual depictions are used to illustrate the preferred embodiment. However, no unnecessary limitations are to be construed by the terms used or illustrations depicted, beyond what is shown in the prior art, since the terms and illustrations are exemplary only, and are not meant to limit the scope of the present invention.
[0132] It is further known that other modifications may be made to the present invention, without departing the scope of the invention, as noted in the appended Claims. | A method of making a set of interlocking floor or wall panels includes providing a single solid layer with a veneer layer on top. The fabrication method involves the use of edge routing using a tongue cutter on one edge and a groove cutter on the opposite edge to form the edge shapes equivalent to those of the previous embodiment. If two routing heads are spaced apart the appropriate distance for a particular sized panel, a single pass can form a tongue on one edge and a groove on the opposite edge simultaneously. One cutter is spun clockwise while the second is spun counterclockwise to equalize the forces on the panel. Thus two passes are needed to form the edges of a panel. The veneer layer, which may be bamboo, birch, or other woods such as cherry wood, is adhesively bonded to the top surface. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to dynamic testing of ground support bolts such as anchor/rock bolts.
BACKGROUND TO THE INVENTION
[0002] Rock bolts are long anchor bolts used to stabilise excavations in rock, such as tunnels and rock faces. A rock bolt transfers load at the exterior surface of the rock into the interior mass of the rock. Anchor bolts are used to securely attach objects to rock or concrete surfaces.
[0003] The 1890s first saw the use of rock bolts. The St Joseph Lead Mine in the USA in the 1920s is recorded as having used rock bolts.
[0004] Australia and the USA have both been recorded as using rock bolts in civil applications in the late 1940s. In 1947 Australian engineers were reported as experimenting with four metre long expanding anchor rock bolts during work on the Snowy Mountain scheme.
[0005] Rock bolts are typically installed in a pattern, the actual arrangement depending on the type of rock (rock quality—position and type of fractures already present, strength of the rock and its propensity to fracture etc.), the type of excavation (tunnel, cut face etc.) and the surrounding geology/geography (risk of seismic activity and any nearby underground or overground workings/structures).
[0006] Both rock bolts and anchor bolts can be used to retain a metal (wire) mesh over a rock face to reduce risk of loose material or rock fall that might injure personnel, damage vehicles/equipment and/or block a tunnel.
[0007] As with anchor bolts, there are many types of proprietary rock bolt designs. Typically a mechanical means, epoxy means or combination of both is used to set the bolt into the rock/concrete.
[0008] Rock bolts work by ‘knitting’ the rock mass together sufficiently before it can move enough to loosen and fail. Rock bolts can become ‘seized’ throughout their length by small shears in the rock mass, so they are not fully dependent on their pull-out strength.
[0009] In the case of a rock bolt, it is important to ensure that the rock bolt is capable of retaining the rock in situ when installed. In the case of an anchor bolt, it is important to ensure the item secured by the bolt is safely retained.
[0010] Static testing is an alternative form of test. This can be carried out in a laboratory or in situ. A continuous load is applied to the rock bolt, usually hydraulically. However, static testing does not simulate the ‘shock’ loading to the bolt present in dynamic testing.
[0011] Dynamic tests are conducted to ensure the respective bolt can operate as required. For rock bolts, a dynamic test is carried out in laboratory using a simulated bore-hole whereby the rock bolt is secured in a cement/resin mix inserted into a hollow (steel) tube. The tube is supported as a load acts on the head of the rock bot. This involves hydraulically applying a pull out force to the rock bolt.
[0012] Whilst laboratory simulation is useful, it does not accurately recreate working conditions and cannot perform an in-situ dynamic test on a bolt for the actual rock. Laboratory dynamic testing involves setting the rock bolt in the tube and suspending the tube and rock bolt from a raised support. A weight is dropped a preset distance to apply a shock load to the head of the bolt. The amount of weight and distance dropped determines the amount of force applied to the rock bolt.
[0013] Another form of laboratory testing involves dropping the rock bolt and tube combination together with a weight attached to the rock bolt. Fall of the rock bolt and tube is arrested once the required velocity is reached, but the weight is allowed to continue and thereby applies a load to the rock bolt. This method is said to better simulate the movement of the rock before the rock face fails (i.e. during a seismic event). Such testing is carried out by the Western Australian School of Mines (WASM) and is known as the WASM momentum transfer concept.
[0014] With the aforementioned in mind, the resent invention has been developed in order to provide improved in situ dynamic testing for rock bolts (and optionally anchor bolts).
SUMMARY OF THE INVENTION
[0015] The present invention provides in one aspect a connector to attach a loading device to an in situ ground support bolt, such as a rock bolt or anchor bolt in a rock or concrete substrate, the connector including a body, a first attachment means to attach the body to an in situ rock bolt or anchor bolt, and a loading device connection.
[0016] The loading device connection may include a second attachment means to releasably attach the loading device to the body.
[0017] The body may be unitary or may include multiple portions. For example, the body may be divided into portions that are releasably connectable together by one or more integral or detachable fastening means.
[0018] The connector may include at least one first curved surface on a cavity within the body, and a corresponding second curved face associated with the first attachment means. The first and second curved faces permit relative movement of the first attachment means and the body.
[0019] The connector may include a third curved surface, which may be within the first cavity or may be within a second cavity of the body. A fourth curved surface may contact the third curved surface to allow relative movement of the loading device and the body.
[0020] The cooperating first and second curved surfaces may be complimentary part spherical surfaces, such that movement of one surface relative to the other is multi directional. Likewise, the cooperating third and fourth surfaces may be part spherical surfaces, such that movement of the third surface relative to the fourth surface is multi dimensional. The part spherical surfaces allow for the rock bolt not being vertical in situ. Often rock bolts are angled from vertical into the rock. Relative movement of the first attachment means to the body, and the body to the loading device, allows the connector to transfer impact forces from a vertically dropped weight into the non-vertical rock bolt.
[0021] The first attachment means may include rock bolt connection means to attach the connector to the rock bolt. The rock bolt connection means may include an aperture to receive a shaft portion of the rock bolt. A nut on the external exposed end of the rock bolt may be used to retain the first attachment means to the rock bolt. Preferably the attachment via the nut of the rock bolt transfers the test load forces to the rock bolt.
[0022] Preferably the body has two or more portions arranged to be releasably held together by one or more fasteners. Release of the one or more fasteners allows the body to separate such that at least one of said portions can be removed.
[0023] The body may include two halves that are held together, in use, by the one or more fasteners. The one or more fasteners may include screw thread fasteners (such as bolts) directly into/through the body portions. Alternatively, or in addition, one or more retaining plates may be used. A said retaining plate may include a metal ring with holes therethrough to receive bolts. Bolts may be passed through aligned holes on each ring and nuts attached to the bolts to retain the two halves tightly together once the nuts and bolts are tightened.
[0024] The portions of the body may include flanges or lips, each flange or lip acting as a stop for one of the plates. Thus, when the bolts and nuts are tightened, the rings apply forces to the flanges/lips to hold the two halves together.
[0025] One or more forms of the present invention includes means to prevent damage to an electrical connector of a load cell provided within the connector. Such protection may include at least one metal projection adjacent the electrical connector. For example, a pin or bolt projecting above the load cell electrical connector and a tab of a washer projecting below the load cell electrical connector.
[0026] A further aspect of the present invention provides a dynamic testing system for testing rock bolts and anchor bolts in situ, the system including a loading device and a connector to releasably attach the loading device to an in situ rock bolt or anchor bolt, the loading device including at least one releasable weight to apply an impact load through the connector to the rock bolt or anchor bolt when released, and a weight release device, the connector including at least two portions releasably connectable together.
[0027] The system may include the abovementioned connector and features thereof.
[0028] A method of testing a rock bolt or anchor bolt in situ, the method including connecting a connector to an exposed portion of the rock or anchor bolt, attaching a weight drop assembly to the connector, providing a weight release mechanism to remotely release the weights during testing, the connector including at least one curved surface allowing the weight drop assembly to hang at or near vertical if the rock bolt or anchor bolt in situ is not vertical.
[0029] One or more forms of the present invention advantageously provides for in-situ dynamic testing of ground support members (such as rock bolts) with the ability to record load and displacement of the ground support member (e.g. rock bolt). There are no assumptions required with the rig or the testing, as the rock bolts are already installed in site rock and loaded under test as required.
[0030] Some features and benefits of the system include:
[0031] The test system (Dynamic Testing Rig) can be readily transported to any mine site. No requirement for testing to be restricted to an offsite test facility.
[0032] The test system (rig) is fully self contained (preferably only requires access to mine supply air to run the lifting hoist, though bottled compressed air/nitrogen can be brought in).
[0033] Requires only one person, such as an IT (Integrated tool-handler), to assemble and disassemble the test system.
[0034] Static test on bolt prior to dynamic test (optional if required).
[0035] Energy application levels are readily adjustable. For example, in increments of 8.2 kJ (with optional minor ‘fine tuning’ adjustments of 1.8 kJ).
[0036] Can be used to test any dynamic bolt in-situ. Custom dynamic collars (connector halves) may be provided.
[0037] Repeated loading on single bolts possible.
[0038] Allows free displacement until drop rig impacts with floor (not typically experienced).
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] Embodiments of the present invention will hereinafter be described with reference to the accompanying drawings, in which:
[0040] FIGS. 1 to 3 show an example of a connector and test system utilising the connector according to an embodiment of the present invention.
[0041] FIG. 4 shows a cross section in perspective of an alternative embodiment of the connector.
[0042] FIGS. 5 and 6 show perspective ( FIG. 5 ) and side sectional view ( FIG. 6 ) of a test system according to an embodiment of the present invention.
[0043] FIG. 7 shows a nut threaded onto an exposed end of a rebar ground support bolt to apply an adapter or the first attachment means to the bolt to then receive the connector according to an embodiment of the present invention.
[0044] FIG. 8 shows an adapter threaded onto an external thread on a nut of a ground support bolt (such as a rock bolt) to retain a connector on the bolt according to an embodiment of the present invention.
[0045] FIGS. 9 and 10 show side on external views of the connector forming part of a dynamic testing rig/assembly according to an embodiment of the present invention.
[0046] FIG. 11 shows in perspective view the connector of FIGS. 9 and 10 .
[0047] FIG. 12 shows a cutaway view of the connector of FIGS. 9-11 and showing the internal arrangement of components.
[0048] FIG. 13 shows a sectional view through the embodiment shown in FIGS. 9 to 12 .
[0049] FIGS. 14 a and 14 b show respective side partial cutaway ( FIG. 14 a ) and perspective partial cutaway ( FIG. 14 b ) of an upper portion of the dynamic testing system including the connector and as attached to a non-vertical ground support bolt in-situ in a mine roof.
[0050] FIGS. 15 and 16 show perspective and side sectional views of the dynamic testing assembly/rig with suspended weights according to an embodiment of the present invention.
[0051] FIG. 17 shows a chart of energy displacement performance from in-situ tests conducted at two mine sites.
DESCRIPTION OF PREFERRED EMBODIMENT
[0052] FIGS. 1 to 3 show an embodiment of a dynamic test system for rock bolts. It will be appreciated that the same system can be used to test anchor bolts in rock and concrete by selecting the amount of weight and drop height for the type of anchor bolt (or rock bolt) for a given application.
[0053] As shown in FIG. 1 , a rock bolt 10 is set vertically in an overhead mass of rock 12 (such as a roof of a tunnel). A connector 14 connects the head end of the rock bolt to a shaft 16 . A weight 18 is mounted for movement along the shaft when released by a quick release mechanism 20 . The weight comprises a container 22 to hold multiple individual weights 24 . The amount of individual weights in the container controls the total weight of the container and weights for a required test.
[0054] It will be appreciated that alternative weights can be used. For example, flat plate weights slotted onto the shaft rather than loose weights in a container. A stop member 26 prevents the container/weights coming off the end 30 of the shaft. A threaded nut may be provided to act as or retain the stop member.
[0055] The connector 14 is vertically divided into two halves 14 a, 14 b. (see FIGS. 2 and 3 for detail). Which clasp around the head end of the rock bolt and the upper end of the shaft.
[0056] As shown in FIG. 2 , a first attachment means 32 retains the nut 36 and washer 38 at the head end of the rock bolt. The first attachment means has a curved surface 40 that contacts a corresponding curved surface 42 formed on the inside faces of the two halves of the connector. The mutually curved contact surfaces 40 , 42 allow the connector several angular degrees of movement about the rock bolt head. This positional ability accommodates the test system acting on a non-vertical rock bolt. A tapered opening 44 with tapered surface on the connector allows for the movement of the connector relative to the shaft/head of the rock bolt and acts as a stop limit.
[0057] The lower end of the connector 48 accommodates a second attachment means 50 that has an aperture therethrough to receive the upper end of the shaft (not shown in FIG. 2 ). A nut retains the upper end of the shaft in a similar way to the head of the rock bolt against the first attachment means. The second attachment means can attach by screw thread onto the upper end of the shaft.
[0058] The second attachment means includes a curved surface 54 and the two halves of the connector form a mutually curved interior surface 56 that contacts the curved surface of the second attachment means to allow angular degrees of freedom of movement of the second attachment means, and therefore the shaft and weights, relative to the connector (and therefore relative to the rock bolt). This arrangement allows the test rig to act on the in situ rock bolt even if the rock bolt is not vertical.
[0059] The connector 14 shown in FIGS. 1 to 3 has multiple holes 60 through paired flanges 62 a, 62 b and 64 a, 64 b. Bolts through the holes in the flanges are used to hold the two halves together in situ.
[0060] The alternative embodiment of a connector 100 of the present invention shown in FIG. 4 operates in a similar manner to the connector shown in FIGS. 1 to 3 . The connector 100 includes two vertically separated portions 100 a, 100 b. Each portion includes at least one handle 102 to assist with lifting and holding each portion when mounting to the rock bolt.
[0061] It will be appreciated that the head nut of the rock bolt may or may not be loosened or removed so that the first attachment means can be mounted to the head of the rock bolt after installation of the rock bolt. Alternatively, during installation of the rock bolt, the first attachment means or an adapter or spacer for connection of the connector can be attached to the rock bolt so that the head nut of the rock bolt is not removed to connect the connector.
[0062] The end of the rock bolt exposed out of the rock passes through the aperture 114 in the first attachment means. The two halves 100 a, 100 b of the connector 100 are then placed about the first attachment means with the second attachment means 116 suspending the shaft 118 via a shaft adapter 120 and nut 122 .
[0063] Alternatively, an adapter or the first attachment means can be retain on an exposed end of a ground support bolt (such as a rock bolt) by a nut threaded onto the shaft of the bolt. As shown in FIG. 7 , a nut 220 can be threaded onto a shaft 222 of the bolt.
[0064] The shaft of the bolt can be rebar (reinforcing bar) with a discontinuous external thread formed on its external surface). The nut can be or include a spacer or adapter to retain the connector body, or can retain an adapter or spacer in place.
[0065] As shown in FIG. 8 , the nut on the ground support bolt (rock bolt) can be externally threaded to threadingly receive a spacer or adapter 224 thereon. Thus, the connector can be supported directly on the nut of the ground support bolt.
[0066] Alternatively, the nut of the ground support bolt can be removed and replaced by a spacer/adapter to retain the connector or a spacer/adapter can be added to be retained by the nut.
[0067] Lower 124 and upper 126 rings bolt the two portions 100 a, 100 b together. The bolts 128 can pass through both rings or separate bolts 129 can be used for each ring.
[0068] The connector can be provided with load and/or acceleration sensing devices. For example, an accelerometer 130 can be provided to detect downward movement/acceleration of the connector (and therefore of the connected rock bolt).
[0069] The accelerometer 130 is electrically connected (hard wired or wireless) to communicate with a data receiving means, such as a computer, processor or memory device for later processing of data.
[0070] A load cell 132 can be provided to detect load forces resulting from the impact of the weight(s) and therefore detecting the load applied to the rock bolt. The load cell is applied to a washer or spacer or is formed as a ring between the nut 122 retaining the shaft and the second attachment means 116 . Thus, acceleration data and load data can be gathered and analysed to determined load forces applied to the rock bolt and detect any movement of the rock bolt resulting from the test.
[0071] As with the first attachment means, the second attachment means 116 includes a curved surface 136 arranged to contact a complimentary curved surface 138 on the inside of the cavity formed by the two body portions of the connector.
[0072] The first attachment means 104 has a curved surface 106 that contacts a complimentary curved surface 108 on the inside of the cavity 110 of the connector. The curvature of each surface is preferably part spherical to allow angular degree of freedom for the connector body 112 (comprising the two connected portions) about the head of the rock bolt.
[0073] The test system 200 includes a connector 100 (as shown in FIG. 4 ) from which is suspended a shaft 202 and assembly of weights 204 . FIG. 6 is a cross sectional view, and shows the connector 100 connected to a rock bolt 10 .
[0074] The weights 206 are plates stacked one on top of another to achieve the desired downward force and to apply a required shock force to the rock bolt through the assembly when the weights are dropped and then arrested by the weight stop 208 attached to the lower end of the shaft.
[0075] The weights are supported on a lower plate 210 and safely retained in place by an upper retainer plate 212 by through bolts 214 and retainer nuts 216 . The wavy horizontal lines A,B in FIGS. 5 and 6 indicate that the shaft can be of any desired length.
[0076] In use, the connector is connected to an adapter or to the first attachment means attached to the rock bolt head. The shaft and weights are suspended from the connector. The desired amount of weight is set for release by a release mechanism to allow the weights to drop down the shaft. The shock of the arrested weights is measured as a sudden pull force on the rock bolt, and any movement of the rock bolt and the amount of force applied can be measured respectively by the accelerometer and load cell in the connector. Such dynamic testing on rock bolts or anchor bolts in situ enables the performance of the rock bolt or anchor bolt to be assessed under site specific conditions.
[0077] Benefits of the dynamic test system are that it can apply 25 kJ of energy to the bolt, can detect slip/deformation of the bolt arising from energy application, allows remote release of the weight a a safe distance from the test area, is readily assembled for use and disassembled on site, and can be installed and operated by one or two personnel.
[0078] FIGS. 9 and 10 show respective side views of the connector of a dynamic testing system according to an alternative embodiment of the present invention. Reference numbering is the same as for the embodiment shown and described with reference to FIG. 4 .
[0079] However, the embodiment shown in FIGS. 9 and 10 further includes a bolt 133 projecting through a gap 137 provided between the two halves 100 a, 100 b of the connector when assembled. The bolt, is mounted into the retaining nut 122 immediately above the load cell 132 , and, in conjunction with an additional washer 135 (with its tab 135 a ) below the load cell, helps to protect the load cell 132 and its electrical connector 132 a from impact damage. It was realised during trials of the dynamic testing system that the load cell and/or its electrical connector could become damaged in situations where the connector was initially not vertical when connected to the rock bolt and the load dropped, causing the connector to articulate via the complimentary curved surfaces 106 , 108 and 136 , 138 whereby the electrical connector of the load cell could suffer impact. The bolt and washer protect the load cell, and particularly the load cell electrical connector, during such relative movements of the two halves 100 a, 100 b and the first and second attachment means 104 , 116 .
[0080] The shaft adaptor 120 also includes a releasable locking fastener 141 (e.g. a locking bolt or screw) to help retain the shaft 118 to the adaptor.
[0081] FIG. 11 shows a perspective view of the connector shown in FIGS. 9 and 10 .
[0082] FIG. 12 shows a cutaway view of the connector 100 according to the embodiment discussed above in relation to FIGS. 9 to 11 . The cutaway view shows the nearest connector half 100 a removed and the second connector half 100 b remaining in position.
[0083] The bolt 133 is shown projecting though the opening 137 formed by the cut-outs 143 a, 143 b in the respective connector halves 100 a, 100 b. The washer 135 is shown with washer tab 135 a projecting into the opening 137 . Thus, the load cell 132 and particularly its electrical connector 132 a are protected from impact damage from above by the bolt 133 and from below by the washer and its tab 132 a.
[0084] The mating face 145 of the connector half 102 b shown includes locating projections 147 which match with corresponding recesses in the respective mating face of the other half 100 a for correct positioning when connecting the two halves together.
[0085] FIG. 13 shows a sectional view through the connector 100 . This view clearly shows the internal arrangement of components within the connector of the dynamic testing system. The first connector 104 releasably attaches to the rock bolt/anchor via a nut 149 and shaft 151 of the pre-installed rock bolt/anchor.
[0086] FIGS. 14 a and 14 b show how the connector 100 allows the supported shaft 118 , 202 and weights assembly to be supported vertically from a non-vertical ground support bolt 153 . The cooperating curved surfaces 108 , 138 on the inside of the connector halves 100 a, 100 b allow the upper first connector portion 104 and lower second connector portion 116 to rotate relative to one another and relative to the two halves 100 a, 100 b. Thus, testing of non-vertically installed ground support bolts can carried out in-situ. This helps to ensure that load forces applied through impact of the weights when dropped are transferred through the shaft 118 , through the connector to the ground support bolt as effectively as possible, and such articulation provided by the connector allows more ground support bolts to be tested in situ even if they are non-vertical and thus not ideally positioned. This helps to increase the overall number of ground support bolts tested and thereby improves mine safety.
[0087] FIGS. 15 and 16 show respective perspective and side sectional views of the dynamic testing system 200 of an embodiment of the present invention. The connector 100 previously described above connects overhead to a rock bolt (not shown) in situ in a mine roof, as in FIG. 6 .
[0088] The system as shown in FIGS. 15 and 16 is similar to that system shown and described in relation to FIGS. 5 and 6 . However, the weights 206 are provided in set stacks, each stack comprising a number of weights, and each stack including fork lift lift/lower points 226 a, 226 b allowing groups of weights to be added or removed from the load 204 by a fork lift truck rather than manually moving one weight plate at a time by one or two people.
[0089] Operation of the testing system with the connector has been conducted in-situ at two mine sites.
[0090] A pictorial summary of test data achieved from the two mine site tests is shown FIG. 17 , which shows the data from Table 1 below.
[0091] Rock characteristics from the first mine site test (mine site 1) were UCS (Uniaxial Compressive Strength) of 200-310 MPa and a Q factor (Barton et al 1993) of 25-50.
[0092] For the second mine site test (mine site 2), the rock characteristics were a UCS of around 156 MPa and a Q factor of 2.5.
[0000]
TABLE 1
Bolt
energy
slip
Mine site
No.
drop
(kJ)
(mm)
Mine 1
1
1
17.23
40
1
2
17.23
60
2
1
33.13
207
3
1
33.13
393
4
1
33.13
—
6
1
33.13
—
Mine 2
1
1
17.1
150
1
2
17.1
69
2
1
19.4
407
2
2
19.4
—
4
1
19.4
—
5
1
12.6
119
5
2
12.6
43.5
6
1
12.6
216.6
6
2
12.6
240
8
1
12.6
120
8
2
19.4
85
9
1
26.3
350
[0093] For the testing, although the rock bolts were numbered consecutively 1, 2, 3, 4 . . . etc., some rock bolts were not tested. Hence, rock bolt number 5 not tested at the first mine site and rock bolts 3 and 7 not being tested at the second mine site. The results Table 1 above shows the amount of slippage (movement) of the rock bolt under dynamic test in-situ for a given applied load (energy applied). As can be seen from the table, some rock bolts were tested more than once.
[0094] In use, a required amount of weight is suspended from the in-situ rock bolt/anchor through the connector 100 and shaft 118 , 202 set-up. The weights are raised up the shaft and retained in that raised position via a quick release mechanism. When the quick release mechanism is operated, the weights fall down the shaft and are very rapidly stopped on impact with the base retaining plate 208 and pad 209 . Kinetic energy is thus transferred through the shaft and connector to the rock bolt/anchor. That energy transfer is recorded by the load cell and any movement of the rock bolt/anchor is measured by the accelerometer.
[0095] The connector allows articulation of the shaft and weights relative to the non-vertical rock bolt/anchor so that a vertically applied force is transferred to the non-vertical rock bolt/anchor in-situ in a mine roof. | A connector, an associated dynamic testing system and method for testing rock bolts or rock anchors in situ. The connector is attached to a rock bolt/anchor and supports a hanging load via a shaft. The connector has a body of two halves retaining upper first and lower second connectors having respective curved surfaces. Each of the two halves has a curved inner surface allowing limited relative rotational movement of the first and second connectors relative to the two halves when a load is applied. A load cell and accelerometer register the load applied to the rock bolt/anchor through the connector and any resulting movement of the rock bolt/anchor. | 5 |
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for providing responses to requests of a client, and particularly to a method and apparatus for providing responses to requests of a client that is in an off-line state.
BACKGROUND OF THE INVENTION
The nineties of the 20th century featured a tremendous social technology revolution which by the collaboration of the data processing industry with the consumer electronics industry. Like all other revolutions, it has had a prominent effect on the technology development trend, especially accelerating the development of those technologies which have been in a fledgling state. One main field among these technologies is the transmission of Internet relevant documents, media and applications. The combination of the consumer electronics industry with the data processing industry has greatly prompted demands on versatile communication transmission methods. From being a loose-coupled computer network used for transmitting science and government data, the Internet has entered a strikingly developing era after over ten years of silent existence. With such development, business and consumers can access all the documents, media and programs directly.
The Internet is an open and worldwide computer network which includes lots of connected subnets. It has been developed from the previous American ARPAnet. Now, it mainly uses TCP/IP as the communication protocol. TCP/IP is an acronym for “Transfer Control Protocol/Internet Protocol”, which is a software protocol developed by the U.S. Department of Defense for computer communication. The Internet can be described as a geographically distributed remote computer network system which executes such networking protocols to allow users to share information and interact. Because of this-kind of widely used information sharing, remote networks such as the Internet have been fully developing into the “open” systems. Therefore, users can design their software applications without constraints to perform specific operations or services. The detailed information about the Internet nodes, objects and links can be referred to in the textbook “Mastering the Internet”, authored by G. H. Cady etc., and published by Sybex Corporation in Alameda, Calif. in 1996.
The World Wide Web (WWW) is the Internet multimedia information indexing and retrieving system. WWW clients use Hypertext transfer protocol—HTTP to achieve transaction processing with the Web Server. HTTP is a well known communication protocol. It allows users to use Hypertext Markup Language—HTML, which is a standard web page description language, to access all kinds of files, such as text, graphics, image, audio and video, etc. HTML provides a basic file format, and allows developers to specify links with other servers and files.
The client/server structure is very popular in WWW. In most cases, the Web client uses a browser to send requests to the web server, and to explain and display (or play) the hypertext information and all kinds of multimedia data formats returned from the Web server.
In real client/server network applications, it is not possible for the client-end software to keep online all the time, especially for those executed on mobile devices. Currently, the widely used mobile devices include the notebook PC such as IBM ThinkPad, handheld PC such as 3COM PalmPilot and IBM WorkPad, or many other handheld devices embedded with network connection. Because of the mobility of such devices, it is inconvenient for them to connect to the net in most situations.
When network connection is impossible, it is absolutely necessary for the client side software to keep working off-line, thus not only the handy features of mobile devices but the huge advantages of the Internet could be fully utilized as well.
Currently, the client side software is unable to work normally when off-line unless it has been specifically so designed. Actually, there have been many specific methods to address this problem. But these methods are either for a specific application or for specific hardware. A common and simple method is greatly needed to keep client side software working normally even when it is off-line.
The important difference between on-line and off-line states is that during the on-line state the client can get the response from the server if necessary. But in the latter case, the client is unable to communicate with the server. So, in client/server architecture, client side software is usually unable to keep on working normally during off-line state.
The first objective of this invention is to provide an apparatus for providing responses to requests of an off-line client.
The second objective is to provide a method for providing responses to requests of an off-line client.
The third objective is to provide a computer-readable media for recording programs which respond to the requests of an off-line client.
SUMMARY OF THE INVENTION
To achieve the objectives mentioned above, this invention provides an apparatus for providing responses for requests of an off-line client, characterized by comprising:
a request-response storage ( 703 ), provided in a client machine, which stores a plurality of requests and a plurality of responses;
a network flow redirector ( 701 ), for redirecting requests of the client from a network connection to the client machine itself by modifying system configuration of the client machine when said client is in an off-line state, and for redirecting requests of the client from the client machine itself to the network connection by resuming the system configuration of the client machine when said client leaves the off-line state and enters an on-line state; and
an off-line server ( 702 ), provided in the client machine, for receiving the requests of the client redirected by said network flow redirector ( 701 ) to the client machine itself, generating responses based on requests received, said plurality of requests and said plurality of responses stored in said request-response storage ( 703 ), and returning generated responses to said client as responses of a server.
To achieve the second objective mentioned above, this invention provides a method for providing responses for requests of an off-line client, characterized by comprising steps of:
(a) providing a request-response storage in a client machine, which stores a plurality of requests and a plurality of responses;
(b) redirecting requests of the client from a network connection to the client machine itself by modifying system configuration of the client machine when said client enters an off-line state; and
(c) while said client is in the off-line state, repeatedly performing in the client machine steps of:
(c1) receiving a request redirected to the client machine itself,
(c2) generating a response based on said request, said plurality of requests and said plurality of responses stored in said request-response storage, and
(c3) returning said response to said client as a response of a server.
To achieve the third objective mentioned above, this invention provides a computer-readable media for recording programs, on which a program is recorded for performing steps of:
when it is determined that a client enters an off-line state, modifying system configuration of the client machine, such that requests of the client are redirected from a network connection to the client machine itself; and
while said client is in the off-line state, repeatedly performing following steps in the client machine:
(c1) receiving a request redirected to the client machine itself,
(c2) generating a response based on said request, said plurality of requests and said plurality of responses stored in a request-response storage provided in the client machine, and
(c3) returning said response to said client as a response of a server.
According to the method and device provided in this invention, to allow the client to keep working normally while off-line, there is no need to modify the client software itself, just make some modification in the client machine's system configuration. Thus, the mobility of the client machine is enhanced greatly. The off-line state is no longer an obstacle to the server and the client. Especially for the client-end software of Personal Digital Assistant (PDA) which is very complex, the mobility of the PDA device could be enhanced greatly because of the removal of the need to modify the client software. Furthermore, the user interface remains unchanged when both on-line and off-line, so there is no need to give additional training to the users.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of this invention will become apparent from detailed description of the preferred embodiments in conjunction with attached drawings, in which:
FIG. 1 shows a data processing system which implements this invention;
FIG. 2 shows the high level framework of the components of the data processing system shown in FIG. 1;
FIG. 3 shows a handheld data processing system which implements this invention;
FIG. 4 shows the client/server architecture of a preferred embodiment of this invention;
FIG. 5 shows the client/server architecture of the preferred embodiment of this invention in more detailed framework;
FIG. 6 shows the computer network which exemplifies the preferred embodiment of this invention;
FIG. 7 shows the detailed framework of the apparatus, which offers responses to the off-line client, provided by this invention;
FIG. 8 shows the flowchart of the method, which is used by the off-line client, provided by this invention;
FIG. 9 shows the flowchart of the method, which is used by the client when it ends its off-line state and enters on-line state, provided by this invention;
FIG. 10 gives an example to show the relationship among the internal pages of an insurance company; and
FIG. 11 gives an example to show that a browser could get appropriate responses when off-line.
DETAILED DESCRIPTION OF THE INVENTION
Several specific details will be offered in the following description. It is obviously not necessary for persons skilled in that art to implement this invention using these details. It other cases, the well-known components or circuits are presented merely in the form of a framework to avoid unnecessary details. In most cases, the details like timing sequence, are omitted if such details are not necessary to fully understand this invention and are common knowledge to persons skilled in the art.
Now refer to FIG. 1, it shows a data processing system 20 which implements this invention. This system includes processor 22 , keyboard 82 and display 96 . Keyboard 82 is connected to processor 22 by cable. Display 96 includes display screen 30 , which can be implemented by CRT, LCD or electroluminescent display, etc. The data processing system also includes a pointing device 84 , which can be implemented by tracing ball, joystick, touching board, touching screen or the mouse shown in the figure. This pointing device 84 can be used to move the arrow or cursor on the display screen 30 . Processor 22 can be connected to one or more peripheral devices, such as modem 41 , CD-ROM 78 , network adapter 90 and floppy drive 40 . Each peripheral device can be embedded inside or outside processor 22 . The output devices such as printer 100 could be connected to processor 22 .
It should be acknowledged by persons skilled in the art that display 96 , keyboard 82 and pointing device 84 can all be implemented by several currently well-known components.
Now referring to FIG. 2, the high level framework of the components of the data processing system shown in FIG. 1 are depicted. The data processing system 20 is mainly controlled by the instructions which are readable to the computer. These instructions could be in the form of software, regardless of where or how to store or access the software. The software can be executed on CPU 50 to make the data processing system 20 work.
The storage devices connected to the system bus 5 include RAM 56 , ROM 58 , nonvolatile memory 60 and the circuit used to store and access information. ROM is used to store data that couldn't be modified. On the contrary, data stored in RAM can be modified by CPU 50 or other hardware devices using DMA controller 86 . Nonvolatile memory 60 has the ability to still keep data even when power is down. Nonvolatile memory includes ROM, EPROM, flash memory and battery backup CMOS RAM. As shown in FIG. 2, this kind of battery backup CMOS RAM could be used to store system configuration information.
The extension card or board is a circuit board containing chips and other electronic components. These components are connected to offer additional functions or resources for the computer. In general, the extension card 54 with bus 6 could be used to contain storage, disk controller 66 , video card, parallel and serial port, and embedded modem. For those lap computers, handheld computers or other portable computers, extension card is usually implemented as PC card, as the similar size as the credit card and inserted into the slot beside or in the back of the computer. One example of this kind of slot is PCMCIA(personal computer memory card international association) slot, defining No. 1, 2, 3 card slot. Empty slot 68 could be used to contain all kinds of extension card or PCMCIA card.
Both disk controller 66 and floppy controller 70 include specific integrated circuits and other related circuits. It is their responsibility to instruct and control reading and writing data from/to the hard disk drive 72 and floppy drive 74 respectively. The operations handled by this kind of disk controllers include locating read/write head, arbitrating between the driver and the CPU 50 , and controlling the transmission from/to the storage. A single disk controller can control more than one disk drive. CD-ROM controller 76 could be included in the data processing system 20 , and can read data from CD-ROM 78 . This kind of CD-ROM uses laser components instead of magnetic equipment to read data.
Keyboard-mouse controller 80 is used as an interface between keyboard 82 and pointing device 84 in data processing system 20 . The pointing device is generally used to control an on-screen component. For example, an arrow-like cursor has a hot point which can specify the location of the pointing device when a user clicks on the mouse or presses a key on the keyboard. There are many other pointing devices, such as graphics input board, stylus, light pen, joystick, tracking ball, track board, and the devices with IBM's “TrackPoint” brand.
Communication between the data processing system 20 and other data processing systems can be simplified by the serial port controller 88 , which is connected to system bus 5 , and network adapter 90 . The serial port controller 88 is used to transmit information between computers ( 22 and 122 of FIG. 2 ), or between the computer and peripheral devices, one bit each time in a single line. Serial communication could be either synchronous (controlled by some standards such as clock) or asynchronous (managed by exchanging signals controlling information flow). Interface RS- 232 and RS- 422 are two examples of serial communication standard. As shown in the figure, this kind of serial interface could be used to communicate with modem 41 of FIG. 1 . Modem is a communication device which enables computer to transmit information in the standard telephone line. Modem 41 converts the digital signal of computer to internal clock signal which is suitable for transmitting in telephone line. It can be used to connect the data processing system 20 with an online information service organization such as “PRODIGY” provided by IBM and Sears. This kind of online service provider can offer many software which can be downloaded to the data processing system 20 via modem 41 . Modem 41 can provide connection to several software resources such as server, electronic bulletin board, the Internet and WWW.
The network adapter 90 could be used to connect the data processing system 20 to LAN 94 . LAN 94 can provide the device allowing users to mail and transmit software and information electronically. Besides this, it can also offer distributed processing, using several computers to share the workloads or cooperate while executing one task.
The display 96 controlled by display controller 98 is used to display the video output generated by the data processing system 20 . This kind of video output includes text, graphics, motion picture and movie. The display 96 can be implemented by CRT based video display, LCD based plane display or gas plasma based plane display. The display controller 98 is an electronic component which can be used to generate the video signal transmitted to the display 96 .
The printer 100 could be connected to the data processing system 20 via parallel port controller 102 . It is used to place the text or image produced by the computer to paper or another media such as transparent film. There are several other types of printers such as image setter, graph plotter, or slide recorder, etc. The parallel port controller 102 could be used to transmit multiple data bits and control bits in the line between system bus 5 and another parallel communication device such as printer 100 .
CPU 50 is charge of reading, decoding and executing instructions, and transmitting information from/to other resources via system bus 5 , which is the computer's main data transmitting route. This kind of bus connects all components in the data processing system 20 , also specifying the media which is used to exchange data. As shown in FIG. 2, system bus 5 connects storage 56 , 58 , 60 , CPU 50 and other devices, and enables data exchange among them. Additional bus 6 connects the CDRom 76 and other components on the extension card 54 .
Now referring to FIG. 3, a handheld data processing system 300 which implements this invention is shown. The front board of the system includes display screen 301 , hand writing area 302 , scrolling buttons 303 , and application buttons 304 . Display screen 301 is used to display the information stored in the handheld data processing system 300 . It is touch sensitive, which means it can induce when a user point-clicks the screen by a pen. It can also display the control and configuration information when an application is executing. Hand writing area 302 is used by user to write text by the pen. Scrolling buttons 303 are used to help view the text or other information beyond the display screen 301 , including up scrolling and down scrolling button. Application buttons 304 are used to activate applications, each with a special icon. The handheld data processing system 300 could be WorkPad from IBM, or PalmPilot from 3COM. As for IBM's WorkPad, there are four application buttons in its front board, corresponding to the notepad, address book, task list and memo applications, respectively. In addition, an appropriate pen (not shown in the figure) could be provided together with the handheld data processing system 300 for the special purpose of point clicking display screen 300 or writing on hand writing area 302 .
The high level framework of the handheld data processing system 300 is similar with that shown in FIG. 2 . The difference is that some components in FIG. 2 are omitted to achieve the small and handy features. In general, the handheld data processing system 300 uses a storage module instead of huge capacity outer storage devices such as disk as memory. Currently, its total memory space is less than 1M. Although the PCMCIA card can be used to extend memory space, the memory capacity after extending is still no more than several megabytes. As for IBM WorkPad, memory space is divided into ROM and RAM, located in the same storage module. ROM has the capacity of 0.5M to 1.5M, RAM has the capacity of 1M at least. The main application group is preset into ROM. Other alternate applications and system extensions can be loaded into RAM. But it is not always feasible with regard to the limitation of the capacity of RAM. Users can upgrade or improve software by changing ROM, or change the system software and application group completely by installing a single storage module. Furthermore, a typical handheld data processing system 300 usually embeds strong network communication ability, which means easy connection to the Internet or WWW.
FIG. 4 shows the client/server architecture of the preferred embodiment of this invention. As shown in this figure, client request (such as the request for news) 91 is sent to server 88 by client 92 . Server 88 could be a remote computer system accessible via the Internet or other communication networks. Client 92 could execute on computer 20 shown in FIG. 1, or the handheld computer 300 shown in FIG. 3 .
When server 88 receives the client's request, it scans and searches the original (for example, uncompressed) information (such as online news or news group), then offers the filtered electronic information as the server response 93 to the client 92 .
Client 92 could be executed on a first computer while the server process could be executed on a second computer wherein they communicate to each other via communication media, thus providing the distribution ability and allowing multiple clients to access the same server at the same time.
As for WWW, the browser process executed on the client machine is in charge of establishing and maintaining connection to the server, and providing information to the user. The server machine executes the appropriate server software, which can provide information to the client in HTTP response. The HTTP response corresponds to the Web page written in HTML, or other data generated by the server.
A uniform resource locator (URL) is used to define linkage when the HTML compatible browser executes on the client machine. The client machine requests the server marked by the linkage, and receives the files in HTML format from the server.
Any browser currently available in the market, such as Netscape's Navigator, Communicator, Microsoft's IE, Mosaic developed by NCSA, Urbana-Champaign, Ill., and Lynx browser, can be used in this invention, as well as any other browser which conforms to HTTP specification.
An Internet service is generally accessed via a unique network address, the aforementioned uniform resource locator (URL), which implies the network route to the server. URL has the special syntax for defining network connection. It is basically divided into two parts, one is the protocol name and the other is the path name of the accessed object. For example, the URL “http://www.uspto.gov” (the home page of the United States Patent and Trademark Office) defines the transfer protocol “http” and the server path “www.uspto.gov”. The server name corresponds to a unique IP address.
Now referring to FIG. 5, the client/server architecture of the preferred embodiment of this invention is shown in more detailed framework. As shown in this figure, client 92 connects to server 88 via network connection 814 . Network connection 814 could be the Internet, intranet or other well-known interconnection. As for the Internet, server 88 is one of the many servers accessible to client 92 . The label 92 represents a client which is a process executed on some client machine, such as a Web browser, mail reader, FTP client, Telnet client, etc.
The client machine could be the desktop, notebook, handheld computer or palm computer. For example, the client machine could be an IBM or IBM compatible computer with OS/2, IBM ThinkPad, another ×86 or pentium based computer with Windows 3.1 or higher version operating system. It could also be an IBM WorkPad with PalmOS, or some kind of PDA with strong network communication ability.
A typical server includes an IBM RISC/6000 with AIX operating system and server program. In this situation, the server usually receives requests from the client via dialing, then performs the appropriate tasks such as finding the specified files or objects to fulfill the client's requests. IBM has issued lots of publications to present the different types of RISC based computers, such as “RS/6000, 7013, 7016 POWERstation and POWERserver hardware technical reference manual”(SA23-2644-00). AIX is presented in detail in the first edition of “AIX operating system technical reference manual” and other publications. Although the structure mentioned above is feasible, it is not the only one, and any other suitable hardware/operating system/server combination also can implement the present invention.
FIG. 6 shows the computer network 80 , which exemplifies the preferred embodiment of this invention. Computer network 80 could be the Internet, or any other well-known computer network with client-server architecture. Persons skilled in the art should know that the Internet is not the only distributed computer network which exemplifies the preferred embodiment of this invention. Computer network 80 could certainly be implemented by other distributed computed networks such as “intranet”.
In theory, the Internet is a huge computer network which includes servers 88 . The clients, usually the personal computer users, could access these servers via some special Internet access providers 84 such as Internet America or online service providers such as America On-Line, Prodigy, Compuserve etc. Each client machine can execute one or more browsers to access servers 88 . Each server 88 is in charge of a so-called “web site”.
It is to be noted that, while the invention involves network transmission, the details of network operations are well known and need not be repeated here.
Referring to FIG. 7, illustration is given of the detailed inventive framework of the apparatus, which offers responses to the off-line client. Client 92 and server 88 shown in this figure are the same as that in FIG. 4 and FIG. 5 . The network connection 814 is identical to the one shown in FIG. 5 . The most fundamental new elements in FIG. 7 are network traffic redirector 701 , off-line server 702 and request-response storage 703 . They construct the basic apparatus of this invention. Network traffic redirector 701 has the following role. When client 92 is in an on-line state, for example, when it is using a browser to browse the web pages of server 88 , network traffic redirector 701 makes no change to the network transmission between client 92 and server 88 at all. In other words, client 92 sends its requests to server 88 via network connection 814 , and when the server 88 receives them, it performs the corresponding tasks and then returns the responses to the client 92 via network connection 814 . When the client is in off-line state, i.e., when the network connection 814 is nonexistent or unable to perform adequately, the network traffic redirector 701 will redirect the requests of client 92 to off-line server 702 in the local machine, which will then respond accordingly (as further detailed below).
The above-mentioned functions of network traffic redirector 701 can be implemented by modifying the system configuration of the client machine. As mentioned above, a URL is basically divided into two parts, one being the protocol name and the other being the path name of the accessed object. For example, the URL “http://www.ibm.com” specifies the server path “www.ibm.com”. The server path name corresponds to a unique IP address. Actually, all data transmission on the Internet is performed by IP address. When a client specifies a server path name, generally some conversion component is needed to do the conversion between server path name and actual IP address. Currently in the Internet, it is up to the domain name server to do this kind of conversion. So, what the network traffic redirector 701 does, when in the off-line state, is convert the server path name to the local IP address of the client machine.
Actually, the IP address conversion process can be performed by the following simple file operations. According to TCP/IP protocol, the operating system will search the “HOSTS” file in the local file system first when it gets a URL. For example, in Windows NT, the “HOSTS” file is stored under the directory “\NT\system32\drivers\etc\”; and for UNIX, this file is stored under the directory “/etc”; and for Windows 95, the file is stored under the directory “\Windows”. A conversion list is contained in this file. Each conversion item occupies a single line. In each line, the IP address is placed in the first column, and the server path name is in the second.
The IP address and the host name should be separated by at least one space. The following is a sample hosts file that includes two records:
102.54.94.97 rhino.acme.com
38.25.63.10 x.acme.com
Since a domain server on the Internet can translate a host name to its IP address , the hosts file in a client machine is usually empty or doesn't exist.
In this invention, the client machine's operating system will redirect requests that are sent to the host name to itself after several records have been added in its hosts file.
For example, suppose the IP address of the client machine is 9.185.8.20. The following records are added to the hosts file on the client machine:
9.185.8.20 www.ibm.com
9.185.8.20 www.uspto.gov
Requests that are sent to www.ibm.com or www.uspto.gov from the client machine would accordingly be redirected to itself If, however, the content of the hosts file on the client machine is cleared in order to recover the system setting, requests that are sent to www.ibm.com or www.uspto.gov would be sent to their real IP address by a domain server.
When the client ( 92 ) is off-line, the network traffic redirector ( 701 ) can redirect requests to the off-line server ( 702 ) and send responses that come from the off-line server ( 702 ) to the client ( 92 ) so that the client ( 92 ) can continue to work. It looks like the client ( 92 ) were on-line.
The request-response storage ( 703 ) stores multiple requests and their corresponding responses. These request-response pairs may be defined by users or be recorded automatically by the following steps according to this invention.
When the client ( 92 ) is on-line, users set its state to record so that the network traffic redirector ( 701 ) always sends requests to the off-line server ( 702 ). Once the client ( 92 ) sends a request, the off-line server ( 702 ) can intercept the request, then the off-line server ( 702 ) sends this request to the server ( 88 ) through the network connection ( 814 ) and receives the response from the server ( 88 ) (See FIG. 7 dot line), then the off-line server ( 702 ) sends the response from the server ( 88 ) to the network traffic redirector ( 701 ). At the same time, the off-line server ( 702 ) saves the intercepted request-response pairs to the request-response storage ( 703 ) in a specific data format. The data format has no restriction on this invention. Actually one can use any data format only if the off-line server ( 702 ) can generate a response according to a requests and multiple requests and responses that are stored in the request-response storage ( 703 ). After the network traffic redirector ( 701 ) receives the response, it sends the response to the client ( 92 ). The process can be repeated until users complete recording.
The content of a request or a response is different from one network protocol to another, such as HTTP ( Hypertext Transfer Protocol), FTP (File Transfer Protocol) and Telnet, as is known to persons skilled in the art.
When the client ( 92 ) is on-line, each request from the client ( 92 ) will be sent to the server ( 88 ) by the network connection ( 814 ) and each response from the server ( 88 ) will be received by the network connection ( 814 ). As mention above, when the client ( 92 ) is off-line or on record status, each request from the client ( 92 ) will be redirected to the off-line server ( 702 ) by the network traffic redirector ( 701 ). Each response from the off-line server ( 702 ) will be sent to the network traffic redirector ( 701 ), then will be sent to the client ( 92 ).
The above description is a method that is used to create multiple requests and responses stored in the request-response storage ( 703 ), defined by users or intercepted by the off-line server ( 702 ) when users set the record status. Users can edit and modify appropriately the content of requests and responses and define default responses for some specific requests in order to simulate the real world. What is more, after the content of the request-response storage ( 703 ) is generated at a client machine, one can simply copy the content to the request-response storage of other client machines in order to avoid repeating the steps of defining, intercepting and editing.
In addition, persons skilled in the art should understand that the storage described herein can be any standalone storage or part of storage at a client machine. For example, it can be a database or file on the disk ( 72 ) or a RAM ( 56 ), both of which are shown in FIG. 2 . Alternatively, it can be a storage card at a palm computer as depicted in FIG. 3 .
When the client ( 92 ) is off-line, the off-line server ( 702 ) begins to work. First of all, the off-line server ( 702 ) receives requests from the client machine itself which have been redirected by the network traffic redirector ( 701 ). Next, then the off-line server generates a corresponding response to the request according to the request and the multiple requests and responses stored in the request-response storage ( 703 ).
The following is a simple process of how the off-line server ( 702 ) generates a response according to a request and multiple requests and responses at the request-response storage ( 703 ):
Assume there are multiple requests and responses in the request-response storage ( 703 ):
R 1 (Request 1 )
S 1 (Response 1 )
R 2 (Request 2 )
S 2 (Response 2 )
Rn (Request n)
Sn ( Response n)
When the off-line server receives a request R, it constructs a response according to the formula (1):
S=f ( R, R 1 , R 2 , . . . , Rn, S 1 , S 2 , . . . , Sn ) (1)
as an example of (1), response S can be one of responses from S 1 to Sn.
Response S can be selected from Responses (S 1 -Sn) according to the formula (2):
S=S 1 , if R logically equals to R 1 ;
S 2 , if R logically equals to R 2 ; (2)
Sn , if R logically equals to Rn ;
Logical equality might be different since the network transfer protocol is different.
With HTTP as an example, suppose the content of R 1 :
GET URL 1
DATE 99.01.01/HTTP
and the content of R:
GET URL 1
DATE 99.01.10/HTTP
Obviously, the content between R 1 and R is different. But the essential part is the same:
GET URL 1 , meaning a request for the network resource marked by URL 1 , therefore the response should be the same. So the off-line server ( 702 ) makes the decision that R logically equals to R 1 and generates a response S that is the same as S 1 at the request-response storage ( 703 ).
Note that the above example is for explanation only. Actual request data may be different from the sample above. But the difference does not limit this invention.
As a general case of formula (1), the Response S can be generated based on Request R, Request R 1 to Rn and Response S 1 to Sn. For a simple example, assume the content R 1 :
http://search.yahoo.com/bin/search?p=game
and the content of R:
http://search.yahoo.com/bin/search?p=Internet
Although R 1 logically equals to R, the parameters in the URL are different. Therefore, Response S 1 don't become Response S. Then the content of Response S could be:
“Sorry, there is no sufficient local data. Cannot search Internet”
According to this invention, the off-line server ( 702 ) can be programmed using sophisticated algorithms to generate an appropriate response according to the received request and the multiple requests and responses stored in the request-response storage ( 703 ). These algorithms don't limit this invention.
The basic devices in this invention include the network traffic redirector ( 701 ), the off-line server ( 702 ) and the request-response storage ( 703 ). There are several devices that can be added to this invention: an off-line request storage ( 705 ) and an actual network service provider ( 706 ). All of them are on the client machine. When the client ( 92 ) is off-line, and upon the off-line server ( 702 ) receiving a client request, it generates a response according to the received request and the multiple requests and responses stored in the request-response storage ( 703 ). It stores the request sequentially in the off-line request storage ( 705 ). When the client ( 92 ) ends off-line state, the off-line request storage ( 705 ) has stored all requests from the client ( 92 ) when it was off-line. When the client ( 92 ) is on-line, the actual network service provider ( 706 ) starts to work. It fetches queued requests from the off-line request storage ( 705 ) one by one, and sends each request to the server ( 88 ) through the network connection ( 814 ). The server ( 88 ) then carries out the task required by the client ( 88 ).
To further enhance the apparatus, the invention may also include an off-line response storage ( 704 ), a comparison device ( 707 ) and a notification device ( 708 ), all of which are looted at the client machine. When the client ( 92 ) is off-line, the off-line server ( 702 ) sends a response to the network traffic redirector ( 701 ), then it stores this response to the off-line response storage ( 704 ) sequentially. Therefore, responses stored in the off-line response storage ( 704 ) correspond to requests stored in the off-line request storage ( 705 ). Of course, persons skilled in the art should understand that the off-line request storage ( 705 ) and the off-line response storage ( 704 ) can be separated into different storage or located at the same storage, as long as the correspondence relationship between requests and responses is maintained. This difference doesn't limit this invention.
When the client ( 92 ) ends its off-line session, not only does the off-line request storage ( 705 ) store all requests sent by the client ( 92 ) when it was off-line, the off-line response storage ( 704 ) also stores all responses that the off-line server ( 702 ) sent to Client 92 . When the client ( 92 ) is on-line, the actual network service provider begins to work. It fetches requests from the off-line request storage ( 705 ) sequentially, then sends each request to the server ( 88 ) through the network connection ( 814 ). The server ( 88 ) actually processes the request from the client ( 92 ). Then, the client ( 82 ) receives the response from the server ( 88 ) through the network connection ( 814 ) and sends it to the comparison device ( 707 ). The comparison device ( 707 ) compares the response with the one corresponding to it which is stored in the off-line response storage ( 704 ). If there is a logical error in the comparison result, the notification device ( 708 ) will be started to report the error to users. One of the effective methods is to call client service software. The actual network service provider ( 706 ) repeats the above process until all requests stored in the off-line request storage ( 705 ) have been processed.
An example that shows how the comparison device ( 707 ) works is given below. It can compare the status code of responses. Suppose Request R 1 stored in the off-line request storage ( 705 ) is sent to the server ( 88 ), then the actual network service provider ( 706 ) receives Response S:
“HTTP 1.0 302 Object Not Found”
and Response S 1 which is stored in the off-line response storage ( 704 ) and corresponding to Request R 1 is:
“HTTP 1.0 200 OK”
The comparison device ( 707 ) compares the status code of S with the one of S 1 and finds the status code does not equal, which means that there is a logical error. In other words, Response S 1 which was sent to the client ( 92 ) is wrong. So the comparison device ( 707 ) starts the notification device ( 708 ) to report this error.
There are certainly other comparison methods that can be used by the actual apparatus. But these minor differences don't limit this invention.
FIG. 8 shows the basic flow chart when the client is off-line. After step 800 , whether the client goes off-line will be decided at step 801 . If no, then it will turn to the flow chart showed in FIG. 9 . If yes, it will go to step 802 . The client machine configuration will be modified at step 802 in order to cause the network traffic to be routed back to the client machine itself The method to modify the client machine configuration has been shown in FIG. 7 and can modify the hosts file at the client machine.
At step 803 , a request from the client will be received, then it will be stored in the off-line request storage at step 804 . A response will be generated according to the received request and the multiple requests and responses stored in the request-response storage at step 805 . The method to generate the response has been described above and shown in FIG. 7 . Then the response from step 805 will be sent to the client at step 806 and stored in the off-line response storage at step 807 . The off-line response storage is also shown in FIG. 7 .
Whether the client ends the off-line operation will be decided at step 808 . If the result is false, then it will turn to step 803 and continue. Otherwise it will finish or turn to the flow chart shown at FIG. 9 . Note that the execute sequence can be changed. For example, step 804 can be executed after step 805 or after step 806 or after step 808 . It is not necessary that step 804 be executed after step 803 . Another example is that step 807 can be executed before step 806 . These subtle differences do not limit this invention. In addition, If the content of the off-line response storage won't be used later, step 807 can be deleted.
In addition, as discussed above, the off-line request storage and the off-line response storage can be separated to standalone storage or located at the same storage only if it can maintain the corresponding relation between requests and responses. This difference doesn't limit this invention.
FIG. 9 shows the flow chart when the client ends the off-line operation and goes on-line. Whether the client goes on-line will be decided at step 901 . If the result is false, then it will turn to step 910 and stop. If the result is true, then it will turn to step 902 . The client machine's configuration will be restored at step 902 in order to route the network traffic to the network connection instead of the client machine itself. The method to modify the client machine's configuration is the same as step 802 and will not be repeated.
Whether requests stored at the off-line request storage have been handled will be determined at step 903 . If the result is false, then it will turn to step 910 and end. Otherwise it will execute step 904 . A request will be fetched from the off-line storage at step 904 . Then the request will be sent to the server through the network connection at step 905 and the server will process the task that the client requests. A response will be received from the server through the network connection at step 906 . Then the response will be compared with the one which is corresponding to the request sent to the server (stored in the off-line response storage at step 807 shown in FIG. 8) at step 907 . Whether the comparison result has a logical error will be decided at step 908 . The meaning of logical error is the same as the one in the comparison device shown in FIG. 7 . If the result is false, it means that the response which was sent to the client at step 806 was correct and the process will go to step 903 . Otherwise, it will turn to step 909 . The logical error will be reported to users appropriately. Users can change the request using a proper method that can be called a client service software, then send the changed request to the server again. After step 909 , it will turn to step 903 .
FIG. 10 shows the relationship among Intranet pages at an insurance company. When a clerk of the insurance company surfs his company's Intranet site using browser (for example Netscape Communicator or Microsoft IE ), the browser sends a request “GET HTTP” to the server. The server receives the request and sends back a HTML describable home page to the browser. The browser receives this HTML file and interprets HTML tags and displays the page. The clerk will see the Intranet home page 1000 of the insurance company. There are two hot links on the page 1000:1. Sell Insurance and 2. Claim.
When the clerk clicks the first hot link (1. Sell Insurance ), the browser will get the URL of the first hot link and generate another request and send it to the server. The server will receive this request and generate a response according to the URL at the request and send it back to the browser. Then the browser will receive this response and display information. The clerk will see the “Selling Form” page 1001. There are three empty fields 1001 A, 1001 B and 1001 C on the form 1001 . When the clerk sells insurance, he will fill these three empty fields according to a customer information. Persons skilled in the art know that data filled at these three empty fields will become parameters stored at a URL. These three empty fields are an example. The number of empty fields relates to a customer information required by the insurance sales business and is not meant, in any way, to limit the invention.
There are two hot links in the page 1001: “OK” and “Cancel”. If the clerk clicks the “OK”, the browser will send a request which includes the above three parameters to the server. If the server handles this request correctly, it will send back another HTTP response and the browser will display the “Sell OK” page 1003 correspondingly. If the clerk clicks “Cancel”, the browser will display the “Sell Cancel” page 1004.
Similarly, when the clerk clicks the second hot link (2. Claim) in the page 1000, the browser will display the “Claim Form” page 1002 from the server. There are three parameters in this page. When the clerk clicks “OK” in the page 1002, the browser will send a URL request which includes three parameters to the server. If the server handles this request correctly, it will send back the “Claim OK” page 1005. If the clerk clicks the “Cancel” in the page 1002, the browser will display the “Claim Cancel” page 1006.
Since the protocol in this example is HTTP, requests and response between the browser and the server conform to the HTTP format.
Assume a clerk of the insurance company wants to visit three customers to sell insurance to two of the customers and process a claim for one of the customers. There are several ways to process this business. The first one is that the clerk invites these three customers to his company and surfs his company's Intranet site and fills the above forms 1001 and 1002 to process the business using the browser. Obviously, it is unrealistic to invite customers to the company. The second one is that the clerk visits the above three customers outside taking a notepad computer or a palm computer which has installed a browser. When he visits each customer, he connects his notepad computer or a palm computer to his company's server by dial-up networking and gets the corresponding forms and fills them and asks the server to process the insurance or claim business. Since there is no guarantee of obtaining a network connection anywhere, the second method has shortcomings considering the low Internet transport speed and the security of network transport.
Inconvenience can be overcome using this invention. For example, before the clerk goes out to visit the above three customers, he connects his notepad computer or his palm computer to the company's server and sets the status to record. Then he surfs his company's Intranet site to go through the home page 1000, Sell Form 1001, Sell OK 1003, Sell Cancel 1004, Claim Form 1002, Claim OK 1005 and Claim Cancel 1006. After he ends surfing, the request-response storage installed at his notepad computer or his palm computer has stored all kinds of requests that need to be sent to the company's server when he goes out and has stored the corresponding responses.
Of course, alternatively, data stored at the request-response storage can be preset and edited by computer professionals of the insurance company. Before each clerk goes out to do business, the preset data will be copied to the request-response storage at his notepad computer or the proper storage card will be installed to his palm computer. When the clerk goes out with the stored information, he doesn't need to connect to the company server, and he is able to work off-line as if he is connected on-line.
FIG. 11 shows how a browser gets responses when it is off-line.
For example, when the clerk visits the first customer, he starts a browser to send a request. According to the method or the apparatus of this invention that can generate a response according to the request sent by the browser and multiple requests and responses stored in the request-response storage, the browser gets the response and displays the home page 1100 . Since the clerk sells insurance to the first customer, he clicks “ 1 . Selling insurance”. The browser gets a response, according to the request sent by the browser and multiple requests and responses stored in the request-response storage, and displays the Sell Form 1101 . The clerk fills the first customer's data to these empty fields 1101 A, 1101 B and 1101 C and clicks “OK”. The browser gets the corresponding response and displays the Selling OK 1103 . Finally, the clerk closes the browser. In this process, the off-line request storage and the off-line response storage installed at the clerk's notepad computer have stored multiple requests and responses.
Similarly, after the clerk visits the second customer, the off-line request storage and the off-line response storage will have additionally stored another set of multiple requests and responses.
When the clerk visits the third customer, he starts a browser. The browser displays the home page 1100. Since he wants to process claim, he clicks “2. Claim”. The browser gets a response, based on the request sent by the browser and multiple requests and responses stored in the request-response storage, and displays the Claim Form 1102 . The clerk fills the customer's data and clicks “OK”. The browser gets the corresponding response and displays the “Claim OK” 1105 . At last, the clerk closes the browser. In this process, the off-line request storage and the off-line response storage installed at the clerk's notepad computer have again recorded the multiple requests and responses associated with the off-line customer interaction.
Therefore, the browser looks like an on-line session in the above process not only to the clerk but also to customers according to the method or the apparatus of this invention.
When the clerk comes back to his office, he connect his notepad computer to the server within the Intranet. Multiple requests stored in the off-line request storage can be automatically sent to the server according to the method or the apparatus of this invention. The server handles the real tasks: two selling insurance and one claiming. Of course, there may be logical errors that need to be reported to users in this process as mentioned above. For example, when selling insurance, the customer filled his age to 90 and the browser displayed the page “Selling OK”. According to the policy of the insurance company, there is no insurance for a person whose age is 90 or over 90. Therefore, when the server handles this task, it sends the response “Sorry, the age can not be over 90.”. So the logical error occurs. For example, the clerk is notified the logical error by the text “A customer's age can not be over 90” displayed in the browser window, then the clerk will verify this information to the customer or modify the customer's wrong data and send the request again.
In addition, the method in this invention can be implemented to a computer application and stored in readable storage media in a computer. The application can be installed to mobile devices such as client software in a practical appliance. The client software doesn't need to be modified and can work off-line. The storage media can have versatile formats, for example magnetic format or optical format. Versatile formats don't limit this invention.
While the preferred embodiments of the present invention have been described in detail with reference to the drawings, various modifications, additions and changes can be made by persons skilled in the art, without departing from the scope and the spirit of this invention as set forth in the appended claims. | An apparatus for providing responses to requests of an off-line client, comprising: a local request-response storage which stores a plurality of requests and a plurality of responses; a network traffic redirector, for redirecting requests of the client to the client machine itself by modifying the system configuration of the client machine when the client is off-line, and for redirecting requests of the client to the network connection by resuming the system configuration of the client machine when the client leaves the off-line state and enters an on-line state; and a local off-line server, for receiving a request of the client redirected to the client machine itself, for generating a response based on the request, the plurality of requests and the plurality of responses stored in the request-response storage, and for returning the response to the client. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a sweeping process for a mass spectrometer that provides a mass analysis by collision induced dissociation or a so-called metastable ion spectrum method.
According to the collision induced dissociation method, sample ions are caused to collide with neutral molecules in a collision chamber that is disposed in the path in which the ions travel, in order to dissociate the ions. Then, spectra are obtained from the resulting daughter ions. According to the metastable ion spectrum method, the metastable ions from sample ions resolve themselves into smaller fragment particles in the Field Tree Drift Region without collision gas, resulting in daughter ions, from which spectra are derived. Both methods have evolved as useful tools for structural analysis of organic compounds or for the study of fragmentation of organic compounds.
To utilize either the collision induced dissociation or the metastable ion spectrum method, a MS/MS instrument is often employed. In this instrument, mass spectrometers are disposed before and after a collision chamber. The present inventor has already proposed a mass spectrometer taking the form of such an MS/MS instrument and in which a superimposed-field mass spectrometric unit constitutes the latter stage of the spectrometer (see U.S. Pat. No. 4,521,687). The structure of this proposed instrument is shown in FIG. 1(a). FIG. 1(b) is a cross-sectional view taken along the line A--A'. In these figures, an ion source 1, an electric field 2, and a magnetic field 3 are arranged in a conventional manner to constitute a double-focusing mass spectrometric unit. This first unit forms a point at which ions are converged, and a collision chamber 5 is located at this point. Disposed between the chamber 5 and a collector 4 is a second mass spectrometric unit having superimposed fields. Specifically, the second unit comprises magnetic pole pieces 6a and 6b for producing a magnetic field in the direction perpendicular to the page, a magnetic field power supply 7 for energizing the pole pieces, a pair of electrodes 8a and 8b for producing a toroidal electric field in the direction perpendicular to the magnetic field, an electric field power supply 9 for generating a voltage applied between the electrodes, auxiliary electrodes 10a and 10b, known as Matsuda plates, mounted between the magnetic pole pieces 6a and 6b on both sides of the toroidal field, and an auxiliary power supply 11 for applying a correcting voltage across the auxiliary electrodes. In this mass spectrometer employing the superimposed fields, the intensity of the magnetic field of the superimposed fields is switched between two levels, and at each of these levels the electric field is swept.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved sweeping process for the collision induced dissociation or the metastable ion spectrum method in a mass spectrometer having superimposed fields.
It is another object of the invention to provide a sweeping process capable of detecting all the daughter ions produced from specific parent ions.
It is a further object of the invention to provide a sweeping process capable of obtaining information about all the parent ions that produce specific daughter ions, the process being customarily called parent ion scan.
It is a yet other object of the invention to provide a sweeping process capable of obtaining information about all the parent ions that produce neutral molecules or particles having specific masses when they undergo cleavage, the process being customarily known as neutral loss scan.
The present invention using a superimposed-field mass spectrometer is characterized in that when daughter ions having a mass m x which are produced from parent ions having a mass m 0 are detected, a voltage Vd x for producing the electric field or the intensity B x of the magnetic field is swept singly or both are swept in an interrelated manner so as to satisfy the relation ##EQU2## where V 00 is the voltage for producing the electric field when ions having infinitely large masses are detected, B 0 is the intensity of the magnetic field when the parent ions are detected, and M 00 is the mass of the parent ions detected when the intensity of the electric field is zero.
When the mass m y of all the parent ions producing daughter ions having a mass m 1 is measured, a voltage Vd y for producing the electric field or the intensity B y of the magnetic field is swept singly or both are swept in an interrelated manner so as to satisfy the relation ##EQU3##
When the mass m 0 of all the parent ions producing neutral particles having a mass m n by cleavage is determined, a voltage Vd n for producing the electric field or the intensity B n of the magnetic field is swept singly or both are swept in an interrelated manner so as to satisfy the relation ##EQU4##
The present invention is hereinafter described in detail with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing the structure of an MS/MS instrument whose latter stage is formed by a superimposed-field mass spectrometric unit;
FIG. 2 is a graph for illustrating the relations given by equations (24) and (5);
FIG. 3 is a graph for illustrating the relations given by equations (29), (24), and (5);
FIG. 4 is a diagram for illustrating a parent ion scan; and
FIG. 5 is a waveform diagram for illustrating a sweeping process according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
It is now assumed that the first mass spectrometric unit of the MS/MS instrument shown in FIG. 1 selects parent ions m 0 + , that the parent ions cleave as given by
m.sub.0.sup.+ →m.sub.x.sup.+ +(m.sub.0 -m.sub.x) (1)
in the collision chamber 5, and that daughter ions m x + and neutral particles (m 0 -m x ) are produced. If the velocity V 0 of the ions does not change before and after cleavage, then the energy of the parent ions m 0 + and the energy of the daughter ions m x + are given by
E.sub.0 =m.sub.0 ·V.sub.0.sup.2 /2 (2)
E.sub.x =m.sub.x ·V.sub.0.sup.2 /2 (3)
Therefore, the following relation holds between E 0 and E x :
E.sub.x =(m.sub.x /m.sub.0)E.sub.0 (4)
The generated daughter ions m x + are introduced into the second mass spectrometric unit having the superimposed fields, together with the parent ions m 0 + which have not been fragmented. We now define symbols to specify the conditions under which the parent ions m 0 + are detected by the second mass spectrometric unit having the superimposed fields, almost all of the symbols being given a subscript "0".
The voltage for producing the electric field of the superimposed fields: Vd 0
The intensity of the magnetic field of the superimposed fields: B 0
The radius of curvature at which ions are deflected in the superimposed fields: a
The radius of curvature at which ions are deflected when only the electric field acts on them: ae 0
The radius of curvature at which ions are deflected when only the magnetic field acts on them: am 0
The mass of the ions detected when the intensity of the electric field is null: M 00
The voltage for producing the electric field when ions having infinitely large masses are detected: V 00
Similarly, we define some other symbols to specify the conditions under which the daughter ions m x + are detected by the mass spectrometric unit having the superimposed fields, almost all the symbols being given a subscript "x".
The voltage for producing the electric field of the superimposed field: Vd x
The intensity of the magnetic field of the superimposed fields: B x
The radius of curvature at which ions are deflected in the superimposed fields: a
The radius of curvature at which ions are deflected when only the electric field acts on them: ae x
The radius of curvature at which ions are deflected when only the magnetic field acts on them: am x
In general, in a superimposed-field mass spectrometric unit or mass spectrometer, the mass m 0 of parent ions are given in terms of M 00 and V 00 as follows: ##EQU5## Since the radius of curvature at which ions are deflected is the sum of the radius of curvature when only the electric field acts on them and the radius of curvature when only the magnetic field acts on them, the following relations hold regarding the parent and daughter ions:
1/a=1/ae.sub.0 +1/am.sub.0 (6)
1/a=1/ae.sub.x +1/am.sub.x (7)
We now discuss the case where the magnetic field intensity B 0 of the superimposed fields is constant. Since the force that ions receive is balanced against the centrifugal force of the circular motion, the following relationships hold:
m.sub.0 V.sub.0.sup.2 /am.sub.0 =ev.sub.0 B.sub.0 (8)
m.sub.x V.sub.0.sup.2 /am.sub.x =ev.sub.0 B.sub.0 (9)
Thus, from equations (8) and (9) we obtain
am.sub.0 /am.sub.x =m.sub.0 /m.sub.x (10)
It is then assumed that the velocity of ions having the mass M 00 which are detected when the intensity of the electric field is zero equals v 00 . Similarly to equations (8) and (9), the following equation results:
M.sub.00 V.sub.00.sup.2 /a=ev.sub.00 B.sub.0 (11)
Because the accelerating voltage is maintained constant, and because the same energy is given to the parent ions m 0 + and to the ions having the mass M 00 , the following equation is obtained:
M.sub.00 V.sub.00.sup.2 /2=m.sub.0 v.sub.0.sup.2 /2 (12)
By eliminating V 00 , B 0 , and e from equations (8), (11), and (12), the following equation is provided: ##EQU6## From this equation (13) and from equation (10), we can have the relations ##EQU7##
With respect to the electric field, the force that ions receive in the field is balanced against the centrifugal force of the circular motion. Therefore, the following equations hold regarding parent and daughter ions:
m.sub.0 v.sub.0.sup.2 /ae.sub.0 =-eE.sub.0 =-eVd.sub.0 /d (15)
m.sub.x v.sub.0.sup.2 /ae.sub.x =-eE.sub.x =-eVd.sub.x /d (16)
where d is the space between the electrodes 8a and 8b. Thus, from equations (15) and (16) we have
ae.sub.0 /ae.sub.x =(Vd.sub.x /Vd.sub.0) (m.sub.0 /m.sub.x) (17)
With respect to the voltage V 00 for producing the electric field that is used to detect parent ions having infinitely large masses, we find
m.sub.z v.sub.z0.sup.2 /a=-eV.sub.00 /d (18)
where m z and V z0 are the mass and the velocity, respectively, of the parent ions. Since they are accelerated by the same accelerating voltage, the energy that the parent ions having infinitely large masses possess is equal to the energy that the parent ions having the mass m 0 possess. Therefore, equation (18) can be written in the form
m.sub.0 v.sub.0.sup.2 /a=-eV.sub.00 /d (19)
From equations (19) and (15), we have
a/ae.sub.0 -Vd.sub.0 /V.sub.00 (20)
The following equations can be derived from equations (20) and (17): ##EQU8## By substituting equations (21) and (14) into equation (7), we have ##EQU9## Equation (22) can also be changed into the form ##EQU10## Either equation (22) or (23) is considered to indicate the relation of the daughter ions m x + to the voltage vd x for producing the dielectric field used to be detected when V 00 , M 00 , and m 0 are given. Especially when the condition in which the parent ions m 0 + are detected is set as an initial condition, the requirement given by equation (5) is satisfied simultaneously. By substracting both sides of equation (5) from both sides of equation (23), we have
m.sub.x /m.sub.0 =1-(Vd.sub.0 -Vd.sub.x)V.sub.00 (24)
Since m 0 , Vd 0 , and V 00 are known, it can be seen from equation (24) that m x is a linear function of Vd x .
FIG. 2 is a graph showing the relations expressed by equations (24) and (5). This graph is formed by giving the mass number M of the detected ions against the voltage Vd for producing the electric field. In FIG. 2, I indicates a sweep curve for parent ions based on equation (5). It can be seen from this graph that the mass is M 00 when the voltage Vd is zero and that the mass is infinity when the voltage is V 00 . Indicated by II is a sweep straight line for daughter ions based on equation (24). This line passes through a point P (Vd 0 , m 0 ), and has a gradient of -m 0 /V 00 . It will be understood from this graph that a daughter ion scan can be made by drawing a line from the point P along the stright line II in the direction indicated by the arrow, i.e., the voltage Vd is swept according to this line. As pointed out already, starting point P indicates the condition in which the parent ions m 0 + is detected. Thus, all the daughter ions stemming from the parent ions are successively detected, and the spectra of the daughter ions can be obtained.
We have thus far set forth the case where the intensity of the magnetic field is constant and the voltage for producing the electric field is swept. We now discuss the situation where both the voltage for producing the electric field and the intensity of the magnetic field are swept to detect identical parent ions m 0 + and daughter ions m x + . When the intensity of the magnetic field changes from B 0 to B x , the voltage V 00 remains constant, but the mass M 00 changes to a value M 00 ', for example, and the voltage for producing the electric field used to detect the same ions is also changed to another value Vd x ', for instance. Then, the following relation holds between Vd x ' and M 00 ', corresponding to equation (23): ##EQU11##
Where only the magnetic field exists, the requirement imposed by equation (11) is met, as mentioned previously. At this time, the energy that the ions having the mass M 00 possess is given by
M.sub.00 v.sub.00.sup.2 /2=eVa (26)
where Va is the voltage for accelerating ions. From equations (26) and (11), we obtain ##EQU12## Exactly the same concept applies to the case where the intensity of the magnetic field is B x . Hence, ##EQU13## Elimination of M 00 from equation (25) using equations (28) and (27) results in ##EQU14## By substituting Vd x ' for Vd x , we have ##EQU15## This equation (29') indicates the most general relation that holds for the superimposed fields when the parent ions break up into the daughter ions.
FIG. 3 is a graph showing the relations expressed by equations (29'), (24), and (5). This graph is given three-dimensionally, with the magnetic field B of the superimposed fields given on the third axis, the first and second axes being similar to those shown in FIG. 2. It is to be noted that the graph of FIG. 2 represents those relations which hold only on the plane B=B 0 in FIG. 3. The point P (Vd 0 , m 0 ) is given as P (Vd 0 , m 0 , B 0 ) in FIG. 3. When the point P is set, i.e., when the parent ions m 0 + are determined, all the daughter ions m x (Vd x , B x ) which are produced from the parent ions m 0 + are expressed as a linear function of the voltage Vd for producing the electric field and of the magnetic field intensity B, and they lie on a plane, or a parallelogram PQOR, one of the corners of which lies at the point P in FIG. 3. Thus, by making a sweep along this plane, a daughter ion scan can be made to detect all the ions originating from the parent ions m 0 + . The daughter ion scan to which the present invention closely pertains is next described in detail by referring to FIG. 3.
First, parent ions m 0 + of interest are selected using the first mass spectrometric unit, which is then made stationary in such a way that the parent ions m 0 + always enter the collision chamber 5. Under this condition, each parent ion m 0 + may cleave to thereby produce one or more daughter ions inside the collision chamber 5. The daughter ions are introduced into the superimposed fields, together with the parent ions which have not been fragmented. The second mass spectrometric unit having the superimposed fields is so set that these parent ions m 0 + are detected. This causes the operating point to be set at the point P (Vd 0 , m 0 , B 0 ). The voltage Vd or the magnetic field intensity is swept singly or both are swept in an interrelated manner from the point P toward the bottom QO of the quadrangle PQOR along an arbitrary curve or straight line on the plane.
The aforementioned sweep made along the line II is an example of this sweep. Since the electric field is swept while the magnetic field is maintained constant, the sweep itself is easy to perform. However, the converging conditions for the superimposed fields are required to be corrected corresponding to the sweep, because the conditions vary during the sweep.
As another example, a sweep is made along a straight line III (PO) which connects the point P and the origin O. Now let an arbitrary point (Vd x , m x , B x ) lie on this line. Then, we have
m.sub.x /m.sub.0 =Vd.sub.x /Vd.sub.0 =B.sub.x /B.sub.0 (30)
Thus, the voltage for producing the electric field should be swept from Vd 0 to zero at a certain gradient, and the intensity of the magnetic field should be swept from B 0 to zero at a certain gradient in step with the sweep of the voltage.
This sweep along the straight line always maintains the value of a/ae x =(Vd x /V 00 )(m 0 /m x ) given by equation (21) constant, thus retaining the converging conditions for the superimposed fields constant. This offers the advantage that the converging conditions are not required to be corrected during the sweep.
As a further example, a sweep is made along a bent line PTO. This sweep may be considered to be the combination of the aforementioned two examples. An arbitrary point on the line PT is given by equation (22) or (23). Assuming that the coordinates of the point T are (Vd x ', m x ', B x '), an arbitrary point (Vd x , m x , B x ) on the line TO is given by the following relations corresponding to equation (30):
m.sub.x /m.sub.x '=Vd.sub.x /Vd.sub.x '=B.sub.x /B.sub.x ' (31)
Referring next to FIG. 4, there are shown five quadrangles P1Q1OR1, P2Q2OR2, P3Q3OR3, P4Q4OR4, and P5Q5OR5 on which daughter ions produced from parent ions m 0 1 + , m 0 2 + , m 0 3 + , m 0 4 + , m 0 5 + are plotted in accordance with the above concept. A plane C is assumed in which m=m 1 . The intersections of the plane C with these quadrangles are straight lines l1, l2, l3, l4, l5, respectively. The daughter ions existing on the lines all have the same mass of m 1 , but the masses of their parent ions are different from each other. Therefore, by making a sweep along the plane C across the lines l1-l5, as for example, along a curve IV, all the parent ions producing daughter ions m 1 + can be obtained. That is, a parent ion scan can be made. It is to be noted, however, that those which are detected after passing through the superimposed fields are, of course, the daughter ions having the mass m 1 at all times. Notice also that the curve IV connects the points on the planes and on the straight line III already described in connection with FIG. 3.
To make the parent ion scan in this way is given by ##EQU16## This has been derived by replacing the daughter and parent ions m x and m 0 of equation (29') with constant values m 1 and m y , respectively. The voltage Vd y and the magnetic field intensity B y have been taken to be variable. This equation (32) is the fundamental formula for attaining a parent ion scan. Various sweeping processes may be contemplated which conform to this equation (32). We present an example of such processes below.
Assuming that the starting point of the sweep lies at (Vd 0 , B 0 , m 00 ) and from equation (32), we obtain ##STR1## If K is made constant, and if Vd y is swept such that
Vd.sub.y /V.sub.00 =K(m.sub.1 /m.sub.y) (34)
holds for all the values of m y , then it follows from equation (32) that B y must be swept according to ##EQU17## Also regarding equation (33), the following equations are derived according to equations (34) and (35):
Vd.sub.0 /V.sub.00 =K(m.sub.1 /m.sub.00) (36) ##EQU18## Elimination of K, M.sub.00, and V.sub.00 from equations (34)-(37) yields
Vd.sub.y /Vd.sub.0 =m.sub.00 /m.sub.y (38) ##EQU19## All the parent ions m.sub.y.sup.+ producing the daughter ions m.sub.1 can be obtained by sweeping Vd.sub.y and B.sub.y in accordance with equations (38) and (39).
More specifically, from equations (38) and (39) we derive the relation
Vd.sub.y /B.sub.y.sup.2 =Vd.sub.0 /B.sub.0.sup.2 (40)
The right side of equation (40) is a constant determined by the starting point of the sweep. Thus, Vd y and B y should be swept while keeping the value of Vd y /B y 2 constant. In particular, the magnetic field intensity of the superimposed fields is changed linearly with time, as shown in FIG. 5(a), by the magnetic field power supply 7. At the same time, the voltage applied by the electric field power supply to produce the electric field of the superimposed fields is changed as a quadratic function with time as shown in FIG. 5(b).
Those which are selected by the superimposed-field mass spectrometric unit and detected are invariably daughter ions m 1 + . The parent ions m y + from which the daughter ions m 1 + are derived vary with the advance of the sweep. Hence, if the mass spectrometric unit at the front stage is fixed as during a daughter ion scan, only specific parent ions are allowed to enter the collision chamber 5. Consequently, when a sweep is done according to equations (38) and (39), it is necessary that a sweep is made in double-focusing mass spectrometric unit consisting of the electric field 2 and the magnetic field 3 at the front stage in step with the sweep made in the superimposed fields, in order that the parent ions producing the daughter ions just selected by the superimposed-field mass spectrometric unit enter the collision chamber 5. Where the mass spectrometric unit at the front stage is not mounted and all the parent ions produced by the ion source 1 go into the collision chamber 5 at the same time, i.e., when a mass spectrometer having a single set of superimposed fields is used rather than an MS/MS instrument, the above requirement, of course, is not required to be met.
The sweep based on equations (38) and (39) is made along the aforementioned curve IV, and during the period of this sweep the value (Vd y /V 00 ) (m y /m 1 ) given by equation (21) is maintained constant at all times. This keeps the convering conditions for the superimposed fields constant, thus eliminating the need to correct for the converging conditions during the sweep.
We have set forth only one example of the sweeping process conforming to equation (32), and various other sweeping processes may be contemplated. In short, a parent ion scan in which all the parent ions producing daughter ions m 1 + can be obtained is made possible by sweeping the voltage for producing the electric field or the magnetic field intensity singly or by sweeping both in an interrelated manner on the plane C across the lines l1-l5 along an appropriate curve or straight line.
The daughter ion scan and the parent ion scan which are closely related to the present invention have been described thus far. Substituting m 0 =m x of equation (1) for m n results in
m.sub.0.sup.+ →m.sub.x.sup.+ +m.sub.n (41)
The above-mentioned daughter ion scan is made under the condition that m 0 is constant. Also, the parent ion scan is made under the condition that m x is constant. Similarly, m n is rendered constant to make a neutral loss scan for obtaining all the parent ions which produce neutral particles m n of the specific mass m n by cleavage. From equation (41) we have
m.sub.x =m.sub.0 -m.sub.n
By inserting this into equation (29), making Vd n and B n variables, and expressing the parent ion m 0 as a function of Vd n and B n in the form of m 0 n (Vd n , B n ), we have ##EQU20## Assuming that the starting point of the sweep is given by m 00 =m 0 n (Vd 0 , B 0 ), equation (42) expresses a curved surface in the same manner as the foregoing daughter ion scan and parent ion scan. Thus, by sweeping both the voltage for producing the electric field and the magnetic field intensity along this curved surface, a scan is made to obtain all the parent ions that give rise to certain neutral particles m n .
As a simple example, a scan can be provided which satisfies the condition ##EQU21## The constant K of this formula is so selected that ##EQU22## In this case, Vd n is given by ##EQU23## Eventually, Vd n is expressed by
(Vd.sub.n -Vd.sub.0)/V.sub.00 =(m.sub.n /m.sub.00)(1-m.sub.00 /m.sub.0 n) (44)
The intensity B n is given by ##EQU24## Thus, it is possible to make a scan to obtain all the parent ions m 0 n arising from the certain neutral particles m n by sweeping Vd n and B n in accordance with equations (44) and (45).
As a further example, we can provide a scan which fulfills the requirement defined by the following equation:
a/ae.sub.x =(Vd.sub.n /V.sub.00)(m.sub.0 n/(m.sub.0 n-m.sub.n))=K (46)
If this requirement is met, the converging conditions are maintained constant and so it is adapted for actual instruments. Under the above condition for the scan, the following equation holds especially at an initial condition m 0 n=m 00 :
(Vd.sub.0 /V.sub.00)(m.sub.00 /(m.sub.00 -m.sub.n))=K (47)
Also, from equations (42) and (46) we have ##EQU25## If B n =B 0 for equation (48), then we can get ##EQU26## Combining equation (46) with equation (47) results in
Vd.sub.n -Vd.sub.0 (1-m.sub.n /m.sub.0 n)/(1-m.sub.n /m.sub.00) (49)
Similarly, combining equation (48) with equation (48') yields ##EQU27## The scan which permits all the parent ions producing the certain neutral particles m n to be obtained can be made by sweeping Vd n and B n in accordance with equations (49) and (50). | A process of obtaining spectra of daughter ions which are produced by collision of sample ions with neutral molecules for dissociating the sample ions in a collision chamber disposed in an ion path to thereby provide a structural analysis of organic compounds. To carry out this process, a mass spectrometer is used which has mass spectrometric units located before and after the collision chamber. The spectrometric unit located behind the chamber has superimposed magnetic field B and electric field E perpendicular to the magnetic field. Daughter ions having a mass m x produced from parent ions having a mass m 0 inside the chamber are detected and measured by sweeping the voltage Vd x for producing the electric field or the intensity B x of the magnetic field singly or sweeping both in an interrelated manner so as to satisfy the relation ##EQU1## where V 00 is the voltage for producing the electric field used to detect the parent ions having infinitely large masses, B 0 is the intensity of the magnetic field when the parent ions are detected, and M 00 is the mass of the parent ions detected when the intensity of the electric field is zero. | 7 |
This application is a continuation-in-part of U.S. patent application Ser. No. 768,784, filed Aug. 23, 1985 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention:
This invention relates to the art of papermaking, and particularly to a method of treating starch-containing paper product at high temperature to improve its properties, including dry and wet stiffness and wet tensile strength.
2. Description of the Prior Art:
In the art of papermaking, it is customary to subject felted fibers to wet pressing and then to drying on heated rolls.
There is currently considerable interest in improving various properties of paper and boards. Quantifiable paper properties include: dry and wet tensile strength, folding endurance, stiffness, compressive strength, and opacity, among others. Which qualities should desirably be enhanced depends upon the intended application of the product. In the case of milk carton board, for example, stiffness is of utmost importance, whereas for linerboard three qualities of particular interest to us are strength, folding endurance, and high humidity compression strength.
All of these properties can be measured by well-known standard tests. As used herein, then, "wet strength" means wet tensile strength as measured by American Society for Testing and Materials (ASTM) Standard D829-48. "Folding endurance" is defined as the number of times a board can be folded in two directions without breaking, under conditions specified in Standard D2176-69. "Stiffness" is defined as flexural rigidity and is determined in a standard TAPPI test as the bending moment in g-cm at a fifteen degree deflection angle. "Linerboard", is a medium-weight paper product used as the facing material in corrugated carton construction. Kraft linerboard is linerboard made according to the kraft process, and is well known in the industry. Folding carton board is a medium to heavy weight paper product made of unbleached and/or bleached pulps having basis weights from 40-350 g/m 2 .
Prior workers in this field have recognized that high-temperature treatment of linerboard can improve its wet strength. See, for example E. Back, "Wet stiffness by heat treatment of the running web", Pulp & Paper Canada, vol. 77, No. 12, pp. 97-106 (December 1976). This increase has been attributed to the development and cross-linking of naturally occurring lignins and other polymers, which phenomenon may be sufficient to preserve product wet strength even where conventional synthetic resins or other binders are entirely omitted.
It is noteworthy that wet strength improvement by heat curing has previously been thought attainable only at the price of increased brittleness (i.e., reduced folding endurance). Embrittled board is not acceptable for many applications involving subsequent deformation, and therefore heat treatment alone, to develop the wet strength of linerboard and carton board, has not gained widespread acceptance. As Dr. Back has pointed out in the article cited above, "the heat treatment conditions must be selected to balance the desirable increase in wet stiffness against the simultaneous embrittlement in dry climates." Also, in U.S. Pat. No. 3,875,680, Dr. Back has disclosed a process for heat treating already manufactured corrugated board to set previously placed resins, wherein the specific purpose is to avoid running embrittled material through a corrugator.
It is plain that improved stiffness and wet strength, on one hand, and improved folding endurance, on the other, were previously thought to be incompatible results.
Every year, the paper industry consumes millions of pounds of starch--an inexpensive natural polymer closely related to cellulose in chemical composition. Preparations of starch are added to papers and board compositions principally to improve their dry strength and their surface properties (J. P. Casey, Pulp and Paper, 3rd edition, pp. 1475-1500, 1688-1694, 1981). However, despite the well-known uses of starch, and of heat treating, separately, papers containing starch have not previously been heat treated to improve wet strength. Indeed, one of ordinary skill would not have expected heat treatment to improve starched paper, since unlike protein, starch does not cross-link when heat is applied.
We have found that heat treatment unexpectedly improves the wet strength of papers and boards containing starch. In its broadest sense, the invention comprises steps of (1) adding starch preparation into the pulp slurry or onto surface of formed paper or board; and then (2) heating the said paper or board to an internal temperature of at least 400° F. (205° C.) for a period of time sufficient to increase the wet strength of the product.
This method produces a product having folding endurance greatly exceeding that of similar product whose stiffness and wet strength have been increased by heat alone, or by starch addition alone. This is clearly shown by the results of our tests, reported below.
If starch is added to the surface of a web, it may be in its native anionic form. However, when starch is added to an aqueous slurry, we prefer to render it cationic, and therefore more soluble, by pretreating it with quaternary ammonium ion salts to give the starch chains net positive charges. Such salts do not affect the paper strength.
We prefer to raise the internal temperature of the board to at least 450° F. (232° C.) during the heat treating step, as greater stiffness and wet strength are then achieved. This may be because at higher temperatures, shorter step duration is necessary to develop bonding, and there is consequently less time for fiber degradation to occur. Also, shorter durations enable one to achieve higher production speeds.
While the invention may be practiced over a range of temperatures, pressures and duration, these factors are interrelated. For example, the use of higher temperatures requires a heat treating step of shorter duration, and vice-versa. For example, at 550° F. (289° C.), a duration of 2 seconds has been found sufficient to obtain the desired improvements, while at 420° F., considerably longer is required.
As an additional step, we prefer to rewet the product, immediately after the heat treatment, to at least 1% moisture by weight. These steps are followed by conventional drying and/or conditioning of the treated product. Of course, those skilled in the art will recognize the necessity of conditioning to a normal moisture content after treatment at high temperature. See, for example, U.S. Pat. No. 3,395,219. A certain amount of rewetting is normally done, and in fact product properties are never even tested prior to conditioning. All conventional rehumidification is done after the product has substantially cooled.
Our rewetting treatment principally differs from conditioning in that we add water, by spraying or otherwise, to a very hot and dry paper or board at the very end of the heat treatment, without intermediate cooling. It is important that water be applied to the product while it is still hot, certainly above 100° C. (212° F.), and preferably above 205° C. (400° F.). Another heat treatment or drying step may follow rewetting, on or off the machine, during a subsequent operation such as sizing, coating or calendering.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As a first step in carrying out the invention, a starch solution is added either to the paper pulp, prior to forming, or to a formed web by sizing or in any of various ways known in the art.
The water content of the web must first be reduced to at most 40% by weight and preferably to within the 10-15% range.
The heat treating and rewetting steps are then carried out, preferably on a papermaking machine, although the test data shown below was developed on a static press in a laboratory. In the heat treating step, sufficient heat is applied to the board to achieve an internal paper temperature of at least 400° F. (205° C.). The heat can be applied in the form of hot air, superheated steam, heated drying cylinders, infrared heaters, or by other means.
Alternatively, the invention may be practiced by heating paper product in an oven after a size-press. The internal temperature of the board should be brought to at least 400° F. for at least 10 seconds. Again, the nature of the heat source is not important.
Following the heat treating step, and while the paper is still hot, water is applied to it, preferably by spraying. Even though one effect of the water application is to cool the paper, it is important that the paper not be allowed to cool substantially before the water application.
The heat treated and rewetted paper is then cooled, conditioned, and calendered according to conventional procedure. The invention has been practiced as described in the following examples. The improvement in board quality will be apparent from an examination of the test results listed in the tables below.
EXAMPLE 1
A commercial bleached kraft board ("C" in the tables) was wetted to contain 10.5% moisture by weight and heat treated at 410° F. (210° C.) for 26.5 seconds ("HT"). The board was conditioned for 48 hours under standard (70° F., 65% relative moisture) conditions. Resultant board properties are listed in Table I.
TABLE I______________________________________ Heat Control Treated Board Example 1Properties (C) (HT)______________________________________Basis weight 139.5 136.3(lb/3000 ft.sup.2)Caliper (mils) 15.1 15.6Taber stiffness (gm-cm) 90/38 86/36corrected for basis weightStiffness improvement % -- -4/-5Dry Tensile lb/in 45/26.1 43.5/30.7(MD/CD)Wet Tensile, lb/in 1.6/1.1 4.5/3.2(MD/CD)Wet Strength Retention, 3.6/4.2 10.3/10.4% (MD/CD)Cracking resistance % 98/100 99/99not crackedMIT Fold, count 55/38 39/43______________________________________
EXAMPLE 2
The bleached kraft board in Example 1 was sized with corn starch (pick-up was 2.8 lb/3000 ft 2 ). One portion of the sized board was conventionally dried (110° C. for 9 seconds, "C" in the table). A second portion was heat treated at 410° F. (210° C.) for 28.8 seconds, without intermediate drying ("HT"). A third portion of the sized board was heat treated for 14.3 seconds under identical conditions, rewetted by a water spray on both sides to contain 15% moisture by weight and heat treated again for 14.3 seconds ("HT+RW"). The board was conditioned for 48 hours under standard conditions. Resultant board properties are listed in Table II. Notably, conventional drying did not improve the wet tensile of the sized board vs. the unsized one; however, both the wet tensile and stiffness of the heat-treated sized board is higher than that of the unsized board.
TABLE II______________________________________ Control Heat Twice Board Treated RewettedProperties (C) (HT) (HT + RW)______________________________________Basis weight 140.5 144.6 141.8(lb/3000 ft.sup.2)Caliper (mils) 15.8 15.9 16.0Taber stiffness 122/71 136/71 134/66(gm-cm)Stiffness improvement % -- +11/0 +10/-7Dry Tensile lb/in 68.0/43.7 70.4/41.6 70.3/43.2(MD/CD)Wet Tensile, lb/in 1.8/1.3 5.6/3.9 3.7/2.3(MD/CD)Wet Strength Retention, 2.7/3.0 8.0/9.4 5.3/5.3% (MD/CD)Cracking resistance 99/100 21/86 96/99% not crackedMIT Fold, count 64/84 10/13 21/72______________________________________
EXAMPLE 3
A mill sized (corn starch added at the mill, 2.4% pickup) bleached kraft board sample (C) was wetted to 10.9% moisture content and then treated at 410° F. (210° C.) for 15 seconds (HT). A portion of heat-treated board was rewetted and dried conventionally (HT & RW). All the samples were conditioned for 48 hours under standard conditions. Properties of these samples are given in Table III.
TABLE III______________________________________ Control Heat Board Treated RewettedProperties (C) (HT) (HT&RW)______________________________________Basis weight 153.4 154.5 155.3(lb/3000 ft.sup.2)Caliper (mils) 15.7 16.6 16.1Corrected stiffness 121/60 132/60 133/67Stiffness improvement % -- 9.1/0 9.9/11.7Dry Tensile (MD/CD) 66.1/37.4 72.9/38.1 64.2/48.5Wet Tensile, (MD/CD) 2.5/1.6 5.7/3.6 5.0/3.7Wet Strength Retention, 6.6/4.4 14.9/9.4 10.3/7.5% (MD/CD)Cracking resistance 100/100 85/7 94/58% not cracked______________________________________
EXAMPLE 4
Three unbleached kraft linerboard samples (C) were sized with different amounts of corn starch and then heat treated at 406° F. (208° C.) for 30 seconds (HT). All the samples were conditioned for 48 hours under standard conditions. Resultant linerboard properties are given in Table IV. An improvement in wet strength in observable for the starch-sized samples; the improvement increases with increases in cornstarch addition.
TABLE IV______________________________________ HEAT TREATED PLUS CORNSTARCH, CONTROL % ADD-ONProperties no HT HT 0.3 0.6 1.0______________________________________Basis weight 42.7 42.8 42.6 43.5 43.4(lb/1000 ft.sup.2)Caliper (mils) 13.1 13.4 13.7 13.8 13.6Taber Stiffness 92.5 100.5 91.7 94.5 94.5(g-cm)Dry Tensile, 105.3 87.7 89.9 93.9 97.7lb/in.Wet Tensile, 7.9 13.8 14.6 16.8 18.2lb/in.Wet Strength 7.5 15.7 15.5 17.9 18.6Retention, %MIT Fold 1702 2064 1389 1435 1740______________________________________
EXAMPLE 5
A sample of never dried kraft linerboard grade pulp having a kappa number at 110 and Canadian Standard Freeness of 750 was slurried in water and various starch preparations were added to the slurry in the amount of 1% of the oven dried pulp weight. The starches were "cooked" in water according to conventional practice to contain 8% of starch by weight. A dispersion of the pulp fibers was converted to handsheets using 12×12 inch square sheet mold. The quantity of the fibers in the dispersion was adjusted to give a sheet weight of 19 grams in the oven dry state, said weight being close to that of an air dried, 42 lb/1000 ft 2 commercial linerboard sheet. The sheets were pressed at 60 psi prior to further treatments. A control sample (C) of handsheets was dried in a conventional dryer (Emerson speed dryer, model 10) at 230° F. (110° C.). The rest of the samples were heat treated at 428° F. (220° C.) for 15 seconds (HT). All the samples were conditioned for 48 hours under standard conditions. Resultant properties are listed in Table V. One can see that wet tensile of samples containing starch is higher than that of both control and heat treated samples not containing starch.
TABLE V__________________________________________________________________________ HEAT-TREATED WITH 50:50 NOT POTATO HEAT NO STARCH: TREATED ADDI- CATIONIC CORN POTATO CAT.Properties CONTROL TIVES STARCH STARCH STARCH STARCH__________________________________________________________________________Basis weight 41.0 40.8 42.5 43.9 42.5 43.6(lb/1000 ft.sup.2)Caliper (mils) 13.4 12.8 13.3 13.8 13.1 13.9Taber Stiff- 103.3 93.0 127.5 121.0 89.0 113.0ness (gm-cm)Dry Tensile, 6.5 13.2 20.4 15.8 20.9 15.2lb/in.Wet Tensile, 0.5 2.1 4.0 2.2 4.6 2.1lb/in.Wet Strength 8.0 15.6 19.7 13.7 22.2 13.8Retention, %MIT Fold 2108 1385 1172 803 479 1225__________________________________________________________________________
Inasmuch as the invention is subject to many variations and changes in detail, the foregoing description and examples should be taken as merely illustrative of the invention defined by the following claims. | A paper product having high stiffness, wet strength, and opacity, and good folding endurance is produced by subjecting a paper web containing a starch additive to high temperature heat treatment. | 3 |
BACKGROUND OF THE INVENTION
The invention relates to a display device comprising an electro-optical display medium between two supporting plates, a system of picture elements arranged in rows and columns, with each picture element being formed by picture electrodes arranged on the facing surfaces of the supporting plates, and a system of row and column electrodes for presenting selection and data signals by means of which a range of voltages dependent on the electro-optical display medium can be presented across the picture elements for the purpose of picture display.
A display device of this type is suitable for displaying alphanumerical information and video information by means of passive elector-optical display media such as liquid crystals, electrophoretic suspensions and electrochromic materials.
A display device ofthe type described in the opening paragraph is known from U.S. Pat. No. 4,811,006, issued March, 1989, in the name of the Applicant. In the device shown in this Application diodes are used as non-linear switching elements in an active matrix, namely two diodes per picture element. Two successive rows of picture elements each time have one row electrode in common. The drive mode is such that in television applications (for example, with a drive mode in accordance with the PAL or NTSC system) the information of two successive even and odd lines is presented across each picture element at an alternating polarity and at the field frequency. The information of a picture element is therefore determined by the average signal of two successive even and odd lines. Since each time two rows of picture electrodes are simultaneously written, because two successive rows each time have one row electrode in common, such a device provides little flexibility as regards the choice of colour filters to be used. In fact, this choice is limited to strip-shaped colour filters.
U.S. patent application Ser. No. 208,185, filed Jun. 16, 1988; in the name of the Applicant describes a picture display device of the type mentioned in the opening paragraph in which the row electrodes are not common and in which the rows of picture elements are separately driven without the omission of common row electrodes, leading to an increase of the number of connections.
This ensures a considerable freedom in the choice of the colour filters to be used.
This is possible by giving the picture elements a given adjustment per row by charging or discharging the capacitances associated with these picture elements after first having discharged or charged them too far (whether or not accurately).
To this end such a picture display device comprises means to apply, prior to selection, an auxiliary voltage across the picture elements beyond or on the limit of the voltage range to be used for picture display.
In the embodiment shown in the said Patent Application diodes are used as non-linear switching elements.
OBJECT AND SUMMARY OF THE INVENTION
The present invention has for its object to provide a device of the type described in the opening paragraph having a high yield which is also realized by the fact that a satisfactorily operating switching unit is substantially always present.
The invention is based on the recognition that this can be achieved with redundancy-increasing measures known per se without affecting the operation of the display device, notably with respect to grey scale adjustment.
To this end a device according to the invention is characterized in that the picture electrodes on one of the supporting plates are electrically connected to the common point of two non-linear switching units which are arranged in series between a column electrode for data signals and an electrode for applying, prior to selection, a reference voltage resulting in; an auxiliary voltage across the picture elements beyond or on the limit of the voltage range to be used for picture display, while at least one non-linear switching unit comprises a plurality of non-linear switching elements.
As a result of such built-in redundancy, it appears that the risk of faulty switching units is reduced by a factor of 100 to 1000 and that the yield is increased by the same factor in the manufacture of such a display device.
The switching units may comprise series arrangements or parallel arrangements of non-linear switching elements, but also combinations thereof.
The auxiliary voltage is, for example, a fixed reference voltage so that all picture elements in a row are first charged negatively or positively to a fixed value and are subsequently charged or discharged to the correct signal value, dependent on the data signals presented.
Since this is effected for each individual row without a subsequent row or a previous row being influenced, the picture information can be adapted to a colour filter to be used, which colour filter may be composed of, for example, triplets as described, for example, in U.S. Pat. No. 4,908,609 in the name of the Applicant, or it may have, for example, a diagonal structure.
Discharging and charging prior to the actual driving operation with the picture information can be effected during the same line period in which the picture information is presented, but also during the preceding line period.
Since each row of picture elements is now separately written, the voltage across these picture elements can also be inverted per row, which leads to a higher face-flicker frequency and hence to a steadier picture.
BRIEF DESCRIPTION OF THE DRAWING
The invention will now be described in greater detail, by way of example, with reference to the accompanying drawings in which
FIG. 1 is a diagrammatic cross-section of a portion of an electro-optic display device, taken on the line I--I in FIG. 2;
FIG. 2 is a diagrammatic plan view of the device of FIG. 1;
FIG. 3 shows the associated transmission/voltage characteristic of a display cell of the device of FIG. 1;
FIG. 4a and 4b are diagrammatic schematic representations of a device of the type shown in FIGS. 1 and 2;
FIG. 5 is a diagrammatic representation of some appropriate drive signals for operation of such a device;
FIG. 6 shows a modification of the arrangement of FIG. 4a;
FIG. 7 shows a first modification of the arrangement of FIG. 4a using redundancy measures according to the invention;
FIG. 8 shows a second modification according to the invention, and
FIG. 9 shows another transmission/voltage characteristic of a display cell.
The Figures are diagrammatic and not to scale. Corresponding components are usually denoted by the same reference numerals.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 show in a diagrammatic cross-section and in a plan view respectively, a part of a liquid crystal display device 1, which has two supporting plates 2 and 3, between which, for example, a twisted nematic or a ferro-electric liquid crystalline material 4 is present. The inner surfaces of the supporting plates 2 and 3 have electrically and chemically insulating layers 5. A plurality of row and column-arranged picture electrodes 6 of indium tin oxide or another electrically conducting transparent material is provided on the supporting plate 2. Likewise, transparent counter electrodes 7 of, for example, indium tin oxide which are in the form of strip-shaped row electrodes 11, are provided on the supporting plate 3. The facing picture electrodes 6, 7 form individually controllable display cells which constitute the picture elements of the display device.
Strip-shaped column electrodes 8 are arranged between the columns of picture electrodes 6. Each picture electrode 6 is connected to a column electrode 8 by means of a switching unit, in this embodiment a diode 9 diagrammatically shown in FIG. 2. As is apparent from FIG. 2, the associated column electrodes 8a, 8b are arranged between two picture electrodes 6a, 6b. Liquid crystal orienting layers 10 are also provided on the inner surfaces of the supporting plates 2 and 3 over the various electrodes. As is known, another orientation state of the liquid crystal molecules and hence an optically different state can be obtained by applying a voltage across the liquid crystal layer 4. As is also known, the display device may be realized as a transmissive or a reflective device and may be provided with one or two polarizers for this purpose.
Auxiliary electrodes 18, each of which has two picture electrodes 6 in common in this embodiment, are arranged on the side of the picture electrodes 6 opposite from that of the column electrodes 8. The auxiliary electrodes 18 connect the picture electrodes 6 to a reference voltage via other switching units, in this embodiment diodes 19, which are diagrammatically shown in FIG. 2. This reference voltage is chosen to be such that, dependent on the voltages used on the selection line (counter electrodes 11) and the electro-optical material used, the capacitance associated with the picture element can always be discharged via the diode 19 to a voltage value beyond or on the limit of the range of transition in the transmission/voltage characteristic of the relevant electro-optical material.
FIG. 3 shows diagrammatically a transmission/voltage characteristic of a display cell as it occurs in the display device of FIGS. 1, 2. Below a given threshold voltage (V 1 or V th ) the cell substantially passes no light, whereas above a given saturation voltage (V 2 or V sat ) the cell is substantially entirely transparent. The intermediate range constitutes the above-mentioned range of transition and is indicated in FIG. 3 by bracket 17. In this respect it is to be noted that the absolute value of the voltage is plotted on the abscissa, because such cells are usually driven at an alternating voltage.
FIGS. 4a and 4b show diagrammatically a display device of the type shown in FIGS. 1, 2. Picture elements 12 constituted by facing picture electrodes 6 and row electrodes 7, 11 at one end, which together with the column electrodes 8 are arranged in the form of a matrix. The picture elements 12 are connected to column electrodes 8 via diodes 9. They are also connected via diodes 19 to an auxiliary electrode 18, which is common to two diodes 19, 19'.
FIGS. 5a-c show how the drive signals are chosen for a plurality of rows of picture elements 12 in order to write them with picture information which changes sign during each field (for example, in TV applications).
For writing information, a first selection voltage V s1 (see FIG. 5a) is presented on a selection line 11 during a selection period t s , while the information or data voltages V d are simultaneously presented on the column electrodes 8; this leads to a positive voltage across a picture element 12 which represents the information presented.
To prevent degradation of the liquid crystal and to be able to increase the so-called face-flicker frequency, information having an alternating sign is preferably presented across the picture element 12. In a device according to the invention a negative voltage across the picture element 12, which represents the information presented, is achieved by presenting a second selection voltage V s2 while simultaneously presenting inverted data voltages (-V d ) after having discharged the capacitance associated with the picture element 12 too far (or having negatively charged it too far).
From the instant t 0 (see FIG. 5a) a selection voltage V s1 is presented on a row electrode 11 during a selection period t s (which in this example is chosen to be equal to a line period for TV applications, namely 64 μsec) while information voltages or data voltages V d are simultaneously presented on the column electrodes 8. After the instant t 1 the row of picture elements 12 is no longer selected because the row electrode 11 receives a voltage V ns1 . This voltage is maintained until just before the next selection of the row of picture elements 12. In this example this is effected by giving the selection line 11 a reset voltage just before selecting the first row of picture elements 12 again, namely at an instant t 3 =t f -t s in which t f represents a field period. The reset voltage and a reference voltage presented on the common point of the diodes 9, 19' can then be chosen to be such that the picture elements 12 are charged negatively to such an extent that the voltage across the row of picture elements lies beyond the range to be used for picture display (to a value of ≦-V sat ). In a subsequent selection period (from t 4 ) they are then charged to the desired value determined by data voltages -V d . To this end the row electrodes receive the voltage V s2 and after the selection period (after t 5 ) has elapsed, they receive a non-selection voltage V ns2 . In this way the voltage across the picture elements is inverted during each field period.
FIG. 5b shows the same voltage variation as FIG. 5a, but is then shifted over a field period plus a selection period (in this case a line period). This provides the possibility of writing two successive rows of picture elements with inverse data voltages with respect to each other. FIG. 5c is identical to FIG. 5a, but is shifted over two selection periods.
For (television) pictures with half the vertical resolution in which the lines of the even and the odd field are written over each other, it is achieved that the picture information changes its sign and is refreshed once per field period. Although the line-flicker frequency is 25 Hz (30 Hz) in this case, a face-flicker frequency of 50 Hz (60 Hz) is achieved between successive rows due to the phase difference of 180° introduced by changing the sign per row.
The selection voltages V s1 and V s2 may of course also be chosen to be shorter than one line period (64 μsec). In this case the reset voltage may alternatively be presented during a part of the line period in which selection takes place, provided there is sufficient time left to charge the picture elements 12. The voltage variation on the electrodes 11 is then effected, for example, in the way as shown diagrammatically in FIG. 5a by means of the broken line 14.
The device shown is very suitable for using a drive method in which the average voltage across a picture element ##EQU1## (see FIG. 3) so that the absolute value of the voltage for the purpose of picture display across the picture elements 12 is substantially limited to the range between V th and V sat .
A satisfactory operation as regards grey scales is obtained if, dependent on the data voltages V d on the column electrodes 8, the voltage values across the picture elements 12 are at most V c +V dmax =V sat and at least V c -V dmax =V th . Elimination of V c yields: |V d | max =1/2(V sat -V th ), that is to say, -1/2(V sat -V th )≦V dmax ≦1/2(V sat -V th ).
In order to charge a row of picture elements 12, for example, positively, the associated row electrode 11 is given a selection voltage V s1 =-V on -1/2(V sat +V th ) in which V on is the forward voltage of the diode 9. The voltage across the picture element 12 is therefore V d -V on -V si ; it ranges between
-1/2(V sat -V th )+1/2(V sat +V th )=V th
and
1/2(V sat -V th )+1/2(V sat +V th )=V sat ,
dependent on V d .
In order to negatively charge the same row of picture elements 12 (in a subsequent field or frame period) at a subsequent selection with inverted data voltages, these are first charged negatively too far by means of a reset voltage V reset on the row electrode 11 via diodes 19 connected to the reference voltage. Subsequently the selected row electrode receives a selection voltage V s2 =V on +1/2(V sat +V th ) (in the same line period or in a subsequent line period). The picture elements 12 which are negatively charged too far are now charged via the diodes 9 to V d -V on -V s2 , that is to say, to values between
-1/2(V sat -V th )-1/2(V sat -V th )=-V sat
and
1/2(V sat -V th )-1/2(V sat -V th )=-V th ,
so that information with the opposite sign is presented across the picture elements 12.
In the case of non-selection the requirement must be satisfied that neither diodes 9 nor diodes 19 can conduct, in other words, for the voltage V A at the junction point 13 it must hold that V a ≧V d and V A ≦V ref or V Amin ≧V Dmax (1) and V Amax ≦V ref (2).
For the lowest non-selection voltage V ns1 it then holds that
(1) V Amin =V ns1 +V th ≧V Dmax =1/2(V sat -V th ),
or
V ns1 ≧1/2(V sat -V th )-V th (3).
It follows from (2) that:
V ns1 +V sat ≦V ref or
V ns1 ≦V ref -V sat (4).
Combination of (3) and (4) yields:
V ref -V sat ≧V ns1 ≧1/2(V sat -V th )-V th
V ref ≧3/2(V sat -V th ) (5).
For the highest non-selection voltage V ns2 it similarly holds that:
V Amin =V ns2 -V sat ≧1/2(V sat -V th ) or
V ns2 ≧1/2(V sat -V th )+V sat (3') and
V ns2 -V th ≦V ref or V ns2 ≦V ref +V th (4').
Combination of (3') and (4') yields:
V ref +V th ≧V ns2 ≧1/2(V sat -V th )+V sat or
V ref ≧3/2(V sat -V th ) (5).
The reference voltage 3/2(V sat -V th ) thus suffices to block the diodes 19, 19' after writing both data and inverted data by the method described above. In summary it holds for the voltages V ns1 , V s1 , V ref and V reset that:
V s1 =-V on -1/2(V sat +V th );
V s2 =-V on +1/2(V sat +V th );
V ns1 =1/2(V sat -V th )-V th ;
V ns2 =1/2(V sat -V th )+V sat ;
V ref =3/2(V sat -V th );
V res =V on +5/2 V sat -3/2 V th .
When reversing the sign of the diodes 9, 19 as is diagrammatically shown in FIG. 4a, the same type of drive mode may be used. Similar relations, be it with reversed sign, then apply to the drive signals.
FIG. 6 shows diagrammatically a modification of the device of FIG. 4a in which per column of picture elements both a column electrode 8 and an auxiliary electrode 18 is present. Otherwise the reference numerals have the same significance as in the previous embodiment. The drive mode is also identical.
As has been stated, the advantage of such a device is, inter alia, that each row of picture elements can be separately driven without extra connection lines being required and with a free choice as regards the colour filters to be used.
In the embodiments described above the devices comprise two switching units, in this case the diodes 9, 19, for each picture element 12. To reduce the risk of poorly functioning picture elements due to non-functioning or poorly functioning switching elements, redundancy is used; for example, two diodes may be arranged in parallel to neutralize the consequences of open connections and two diodes may be arranged in series to neutralize the consequences of a short-circuited diode.
FIG. 7 shows a way in which for a single picture element 12 a switching unit 21 connects the picture element 12 to the auxiliary electrode 18 for the reference voltage. The switching unit comprises two series-arranged diodes 19a, 19b. The reference voltage is adapted in such a way that despite the additional voltage drop across the second diode the picture elements can be negatively charged so far that the voltage across the picture elements lies again beyond the range to be used for picture display (up to a value of ≦-V sat ) and is subsequently charged to the desired value in the same way as described with reference to FIGS. 4 and 5. If one of the diodes 19a, 19b is short-circuited, the relevant picture element 12 is negatively charged to a slightly further extent, but is still charged to the desired value in the subsequent selection period. Hence, such a short circuit does not affect the operation of the display device.
Another error which may occur is an open connection. This can be neutralized by arranging one or more switching elements in parallel with the diode circuit.
This is diagrammatically indicated by means of the diodes 22a, 22b in the relevant embodiment.
In FIG. 8, switching units 9a, 9b, in this embodiment diodes, are arranged in the switching unit 23 so as to neutralize the consequences of a short-circuited diode. In order to cope with the effect of an additional diode in the switching unit, the above-derived selection voltages (for the configuration of FIG. 4a) must be corrected by an amount of -V on , both when charging the display element negatively and when charging it positively.
If one of the diodes 9a, 9b is short-circuited, the picture element 12 is charged too far by an amount of V on during positive charging, but is charged too little in an absolute sense by the same amount V on during negative charging. This is shown diagrammatically in FIG. 9. In this Figure the reference P i is the desired setting value of the grey scale associated with a voltage V i ; the references P p and P n denote the values achieved in practice during positive and negative writing, respectively, when one of the diodes 9a, 9b is short-circuited. Thus the picture element 12 flickers. However, it has been found that flicker of a single picture element is invisible or is hardly visible. Moreover, if two frames are averaged, the effective value of the voltage across the picture element is substantially equal to the desired value.
The grey scale to be set is approached all the better as the voltage drop in the forward direction across the diodes is smaller by an amount of V on . Consequently, Schottky diodes (V on ≈0.3 V) are preferably used for this purpose, but pin diodes (V on ≈0.8 V) are alternatively suitable.
To neutralize the consequences of open connections, diodes 24a, 24b may be arranged in parallel in the same way as for switching unit 21. However, the forward characteristic of the switching unit 23 changes if one of the branches fails. This change is of the order of 18 mV for Schottky diodes. For a typical liquid crystal material (ZLI 84.460) V th =1.5 Volt and V sat =3.6 Volt. The change in this case is only 1/83 of the full range (V sat -V th =2.1 V) and is thus substantially negligible.
If the open connections prevail, for example, because contact holes are so small that they cannot be etched open during manufacture, it is also possible to manufacture larger diodes having larger contact holes.
The above-described measures of providing redundancy in the switching units may lead to a considerably higher yield (an improvement by a factor of 100 to 1000).
The invention is of course not limited to the embodiments shown, but several variations are possible within the scope of the invention.
Non-linear switching elements other than diodes are suitable such as, for example, bipolar transistors with shortcircuited base-collector junctions or MOS transistors whose gate is short-circuited with the drain zone. There are also various possibilities for the diodes themselves. In addition to the diodes which are conventionally used in the technology for display devices, for example, a pn diode, Schottky diode or pin diode formed in monocrystalline, polycrystalline or amorphous silicon, CdSe or another semiconductor material may be considered, while the diodes may be formed both in the vertical and lateral configurations.
Moreover, the availability of a reset voltage renders the above-described device particularly suitable for use in a ferroelectric display medium as described in U.S. Pat. No. 4,840,462 in the name of the Applicant. | In a picture display device driven with an active matrix the voltage across the picture elements is accurately adjusted by discharging or charging the associated capacitances, if necessary, first to beyond the transition range in the transmission/voltage characteristic. Redundancy is advantageously used in the switching units employed for this purpose. | 6 |